Mercury 150 XR2 Rebuild

[ditchdoc666]

Well as most of you know I found a potential problem during a water pump install last week where I had a comp and leakdown test done afterwards,Comp was all good between 122-129 and all cyl were at 6% leakdown except for cyl #1 and it was at 70% leakdown,,well Wreching2 is the bomb on these things,would have never known of the problem if we hadnt checked leakdown at 1/4" past TDC,so today we tore the whole engine apart and found that the the bottom ring on cyl #1 were seized and was the problem,but the good news was we caught it in time w/o any piston or wall damage so he is in the process of rebuilding everything for me,new rings,new boysen reeds,CDI boxs and all the bells and whistles that go with it,will be back on the water in about a week for the break in period,Guys if you need any work done on your engine James is great and explaines things as he goes,never knew what inside of a Merc looked like and now I understand it better,will post some after pics when we are done and let ya'll know the difference it makes in the Ranger.

 

[wrechin2]

Come on now, You are just mad cause I didn't let you take it apart and made you watch!!! I do appreciate the support you gave!! LOL!! At 1/4 it had 54% 3/4 is where it had 70% But then at TDC it had 6% also. You forgot to mention YOU did most of the leakdown test so don't be telling I did it!!!LOL!!

 

[ditchdoc666]

Hey now,I helped sweep,got the baggies for the bolts,and threw stuff away so that counts as helping!!LOL Thanks for all you helped me with understanding the workings of the Merc,can't wait till she is back together and running like she is supposed to,like the guy with the flower shop says "It's Merc time!! Now go order my Parts! LOL emoUpsmile

 

[Oldman]

heck now mine is put on hold,boo hoo---lol

 

[ditchdoc666]

Sorry Larry,I have seen yours and talked about it,very cool,Got some Major TX coming up at the end of the month and glad it wasnt a major problem,wished i could have had that screamer on the floor would have made my boat a missle,a few days late I guess.Thanks

 

[wrechin2]

If we had found it out just a day or 2 sooner, would not have had any down time. Would have sold you mine You would be back on the water tonight!! Oh well, you'll be happy with yours. The 2.0L are workhorses and just about can't kill em. I will get you parts here hopefull 1st of next week Tuesday or Wednesday. What day next week do you want to "help" put it back together? If your good a boy....I may let you torque a few bolts!!LOL!!

 

[ditchdoc666]

Hey James I'm off next tues,wed,fri,sat only day I work is Thursday so call me and let me know,I know it's a tough job but somebody has to do it.LOL

 

[Oldman]

no problem doc.i just got back from his house.shelled out another 500.00.man does it ever end?

 

[wrechin2]

Larry,
We just now getting the parts for yours. Soon we will get it going the right direction.

HARD JOB???? LOL!!! We will play it by ear. I will try to get everything cleaned and ready for install this weekend.
Se ya then!!!

 

[thor]

another old merc trick. pm sent

 

[wrechin2]

Thanks!!!! See, even I get learn new tricks!!! Just when I thought I knew every trick, someone teaches me a new one!!! Thank Thor!!!

 

[Oldman]

no problem,i cant go fishing until this sunday anyway.lol.we are going to have to keep u working day and night.loosing your job may have been a blessing to alot of us fishing freaks.now go to work lol.

 

[wrechin2]

Here is a update... Had a few hold ups on some parts. Installing boyesen reeds in a verticle intake requires some grinding or milling. This is to due to the boyesen being 2 layers and puts the screws further away from the reed cage and you can see there are 60 slots in the intake, 10 per reed slot, I had to mill .035 off of the slots.

 

[wrechin2]

One of the heads has had something hit it and a piston. Here you can see the marks. The ring are fine on the piston so it wasn't a ring. Can't find anything. Must have passed through.

 

[wrechin2]

Shaving the heads to clear up the damage plus give the engine more torque at lower rpms. This will have a better hole shot and stronger acceleration. But first we have to make a FLAT surface. As you can see from the color of the head (with the damaged area and piston) it is casted and that is it. There is no machine work involed in fininshing the head. So we have to bolt the head ,cylinder side down, to the mill table. Running the face mill over the outside of the will make a flat surface, or spots as you can see. Then I flip it over and using the spark plug holes bolt it on top of 2 machined aluminum blocks. The flat spots on the outside of the head contact the aluminum blocks keeping the head cylinder side parallel with the table. Here are some pics of the process. Notice the mirror like surface that is now present on the head. Yes, the mill was running when I took the last pic!!!!! See the blurr!

 

[Oldman]

sounds like he knows what he is doing.lol

 

[ditchdoc666]

emoThumbsup Don't tell him that larry,it will cost me more money!! emoUpsmile James is great on this work and can't wait till Monday till I get it back and go through the break in period,so I can run the boat again been a long two weeks w/o my baby running and looking at it in the garage is depressing.

 

[wrechin2]

emoThanks Doc....Did you see the spot on the head and the piston? I DO NOT know what hit it, maybe it was one of those titanium horse flies I have been hearing alot about!!!LOL!!! Good thing we are doing it monday. It is pouring down rain!!! emoRain

 

[ditchdoc666]

emoThumbsup looking good James,call me today and let me know if reeds came in and all is well for Monday,cya soon

 

[wrechin2]

Sure thing man!!