Mercury 100 FourStroke, Service Manual

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6B-14 - LOWER UNIT 90-830234R3 DECEMBER 1997
4. Stop the engine, turn off the water, and remove
the hose coupling. Reinstall the plug and gasket.
a
b
a - Plug and Gasket
b - Hose Coupling
Liner Replacement
1. Mark the liner mounting bolts for reassembly into
the same holes. Remove the bolts.
2. Remove the liner. If the liner is tight, tap on the in-
ner edge of the liner with a long drift punch
through the intake grate.
NOTE: Apply grease to the liner mounting bolt
threads before assembly.
3. Position the liner into the water intake housing.
Line up one of the liner bolts and lightly thread it
in. It may be necessary to tap or press the liner
into the water intake housing to locate the liner for
installation of the remaining bolts. Torque bolts to
120 lbs. in. (13.6 N·m).
4. Grind off the ends of any bolts that may extend
beyond the inner liner surface.
Jet Drive Removal
1. Shift outboard to NEUTRAL (N) position and dis-
connect the shift linkage.
2. Remove spark plug leads to prevent engine from
starting.
3. Remove the water intake housing that is fastened
with six screws.
4. Straighten the bent tabs (a) on the impeller nut re-
tainer and remove the impeller nut (b).
5. Pull impeller straight off the shaft. If the impeller
is tight, use a hammer and block of wood to rotate
the impeller (clockwise) on the shaft until the key-
way is directly above the flat on the shaft. This will
free the jammed key and allow removal.
a
b
a - Tabs
b - Nut