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  1. #1
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    Mercury 2.5 200hp bad cylinders

    I have. 2001 mercury 2.5L 200hp EFI that lost cylinder 2-4-6 2 came a part and 4 and 6 scuffed. What could of caused this i am in the process of rebuilding powerhead and don't want it to happen again. I have sent ECU for testing and injectors off for cleaning. It is the newer style with the CDM coils and not the switch boxes.

  2. #2
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    either it had a clogged injector and burnt up the #2 piston or something went wrong on the crankshaft or the rings could have just broke. you should be able to look at the piston and tell if it was melted. some pictures might help.

  3. #3
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    Ok I take a few pic of pistons tonight crank and bearings all look good. #2 bent the rod and pulled out of piston and number 4 and 6 looked good untill I pulled pistons out they had some minor scuffing on the sides.
    Attached Thumbnails Attached Thumbnails image.jpg  

  4. #4
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    hard to tell.. but it looks like you may have melted the middle of the piston because of a lean condition (clogged injector) in the cylinder and that caused the rod to push through (thank you ethanol) . looks like melted piston on the cylinder walls.
    scuffs in numbers 4 and 6 are probably normal wear and are also on numbers 1 3 and 5. I would see what needs to be done to number 2 and then do the same to the rest. it probably needs to be bored .010 or .020. do every hole the same and spend the extra money to get good pistons and rings. I would also have a machine shop that knows what they are doing on a outboard check out the crank. I am not sure where lonoke is but there are some great vendors in this forum that will fix you up right.

  5. #5
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    2 major damage 4 pretty bad scoring and 6 light scoring no rings are broke on 4 or 6 and the scoreding is towards the exhaust side. Pistons 1 3 5 look as good as new. I have sent the block off to be repaired but did not send crank becuse all bearings and journals looked good. But should I pack it up and send it to them anyways? Thanks for any help
    Attached Thumbnails Attached Thumbnails image.jpg  

  6. #6
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    Top of pistons on 4 and 6 also look good.
    Attached Thumbnails Attached Thumbnails image.jpg  

  7. #7
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    Scuffing on skirts is temperature, make sure thermostat on starboard side is ok and no blockages on that side. Top of piston damage is lean/ detonation problem. Hard to tell which happened 1st , did this side run too hot 1st and caused drag which resulted in "hot cylinder #2" to detonate (my guess) or did #2 lean 1st and caused extra heat on that side? On right track having fuel system checked but also go through complete cooling system water pump n all.

  8. #8
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    yep...what he said....

  9. #9
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    Ok thank you guys verry much I will replace both thermostats and check all cooling when i rebuild it. As far as if it got hot or not am not sure becuse I bought the boat with the motor bad at a auction. So that is why I am trying to find out as much info as I can with what I have to work with that what would of caused this issue. Becuse the only thing I could think of was that side got hot or there was a fuel or ingtion issue going on the starboard side. I just want to make sure I don't miss something and it end up blowing again the first few houres.

  10. #10
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    was it still runnin on oil injection???????????
    Last edited by johnmiffco; 04-27-2015 at 08:33 PM.

  11. #11
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    Yes it was and I plane on keeping it. Due to it being a bass boat. I kinda ruled the oil injection being bad becuse pistons 1.3. 5. All look great so I would not think it could be oil injection issue but who knows.

  12. #12
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    nothing wrong with inj when keep the safety features hooked up and keep eye on things
    was there oil on the bearings and undamaged parts
    as the other parts looked dry

  13. #13
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    From what I could tell both sides has oil on them because nothing was rusted and boat has been setting over a year.

  14. #14
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    i doubt it was oiler although i take them all off of every rebuild i do , i have had several that look this way in the past 10 years most of the time its heat related issues and a lot of times the sleeve spins in the block causing the very same look as yours, who ever is doing yours make sure he is aware of the sleeve not touching the holder issues because this cause more booms then you can imagine

  15. #15
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    Quote Originally Posted by TEXAS20225 View Post
    i doubt it was oiler although i take them all off of every rebuild i do , i have had several that look this way in the past 10 years most of the time its heat related issues and a lot of times the sleeve spins in the block causing the very same look as yours, who ever is doing yours make sure he is aware of the sleeve not touching the holder issues because this cause more booms then you can imagine
    I have a question then. If it was heat related, did the temp not get hot enough to set off the alarm? or do you think that the alarm is not working? seems like it would have to get pretty hot for the sleeve to spin.

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