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  1. #1
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    Mercury 1994 2.0L 150

    Donít have much of the history on this engine other than it hadnít been run for several years, and by the looks of the cowling, it had been abused before that. It came with the lower part of the airbox full of junk that oozed into the lower left carb, which I believe would be for cylinder #6. It looks like it may have been stored face down in a compost pile.

    Right now I suspect that someone tried to run the engine without cleaning it out first and the junk got sucked in and locked up the engine. Attached are pictures of the evidence so far as it is being dismantled.

    One question I have is can the front half be removed without pulling the engine off the midsection? Also, does the flywheel have to be removed as well? This is the first time Iíve needed to go this far in dismantling one of these.
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  3. #2
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    You will have to remove powerhead and flywheel. Those are good motors.

    Rock
    Team Junk

    No sparkling wiggles in here, only dump truck grinches.

    "Screamin Heathen"

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  5. #3
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    Removed the lower cowl next. The two halves normally rest on those two big rubber bushings, 2 on each side of the motor. In the attached picture of the side of the engine they are in the two lower corners. Once the two halve are unscrewed, they just slide off of those bushings.

    The two halves are attached with 4 screws that run along the bottom of the two halves. Two pictures are attached showing there placement: two towards the front and two towards the back. The 4 screws seemed a little tricky to find if you didn’t know what you are looking for. Also, you need a long ľ drive extension and 5/16” socket to get at them properly.

    Using my pretty high-powered vacuum to suck what I could out of the #6 (bottom) front half opening, and PB Blasted it as well, but the motor is still locked up.

    So now the next step will be to make sure I’ll be able to get the flywheel off.
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  6. #4
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    If you don't already have one pick up a lifting eye with the flywheel puller built in. They are inexpensive and will save you a ton of time and grief.

    Rock
    Team Junk

    No sparkling wiggles in here, only dump truck grinches.

    "Screamin Heathen"

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  8. #5
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    Very good idea… Years ago I made one before I realized you can buy one. We'll see again how it works.

  9. #6
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    Nothing wrong with home made. Many of my tools are just that.

    Rock
    Team Junk

    No sparkling wiggles in here, only dump truck grinches.

    "Screamin Heathen"

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  11. #7
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    Home-made tool worked great. Flywheel is off now. Next will be to see how those powerhead mounting bolts/nuts come out. I expect some trouble there.
    Click image for larger version. 

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  12. #8
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    This is what I’d consider excellent and exciting news on this engine.

    As I was undressing (i.e. remove fuel pump, oil pump, stator) the powerhead a bit to make it easier for removal and opening it up, my son come over to take a look at the progress. I went to give it a spin to show him how locked up it was… but this time it spun freely. This was amazing.

    Best I can determine is that the stator was rusted up, probably rubbing on the magnets. As you can tell from the attached flywheel picture, one of the magnets is broken. Not sure if this happened before I tried to spin it or if I did than when trying to spin it. In any case it spins nicely now with that rusted stator removed.

    One thing I am wondering is if I put the starter back on can I get a valid compression test without putting the reeds back on?

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  13. #9
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    Probably be fine. Compression don't start till after ex port closes.

    Rock
    Team Junk

    No sparkling wiggles in here, only dump truck grinches.

    "Screamin Heathen"

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  15. #10
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    Slight delay on compression check because the starter doesn't seem to want to spin. So I opened it up and see all this white powdery junk and don’t know what to make of the armature. Ordered a new aftermarket replacement figuring it wouldn’t be worth fixing this one.
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  16. #11
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    Got the new starter and bolted it on. Here's the results of the compression test. Cylinder #3 is strangely low and cylinder #6 is strangely high. I’m not so concerned with the high, but the low I am. Does the vacuum valve in #3 happen to affect the compression?

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  17. #12
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    Could be fogger oil or WD or something in high holes. Or maybe all the holes and the low ones are just worn.

  18. #13
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    Pull the heads off.

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  20. #14
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    Good advice. Looks to me like there may be a small leak due to a bad head gasket. The head (#3cyl - middle in the pic) has small gouges matching up with marks in the block. I'm thinking the head has to be replaced or machined to clean that up. Not sure of the tolerances though. If this is all it is I'm feeling lucky.
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  21. #15
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    How's the deck look after you peeled the gasket off? Those gouges look like they are in the squish area of chamber.
    Last edited by FMP; 03-10-2018 at 07:53 PM.

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