$400 and 6 Months Wasted! Picked Up My Re-Sleeved Merc 2.0 Today And Was Shocked

**Gordon02** · 06-13-2019, 11:50 PM

Guys, after waiting for 2 different shops for 6 months and a "special order" LA Sleeve (had to be made super thick), I finally got the call to pick-up my long awaited Merc 2.0L fatblock project block with what was supposed to be a new, sleeved #6 hole.

How does a long running and locally touted shop get by with this kind of product? Now my project is delayed again while I order a special sleeve and find a new shop. I won't be bolting this together.......Gordon

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**Capt.Insane-o** · 06-14-2019, 12:07 AM

Looks about like the xr4 fat block I had years ago. I pulled the heads off and WTF straight from merc it looked just like that. It ran well enough for a ski boat but yeah...

**Jay Smith** · 06-14-2019, 05:43 AM

I use Dwayne Roberie in La. he does my sleeving and bore work on steel and nickel been real pleased and great to work with ...

Jay

**gmjim** · 06-14-2019, 06:15 AM

So how thick is the sleeve?

**Gordon02** · 06-14-2019, 07:30 AM

A #6 rod made a mess of the original bore so it needed a thicker sleeve. They don't stock these..... Part # L-04-OB +40 with OD = 3.418"

**nitro_rat** · 06-14-2019, 08:43 AM

I know fat block 2.0's aren't the most common but I buy old 150's running for $400 and less regularly. Even bought a 175 EFI in pretty good shape for $400. Maybe just find another block?

**rock** · 06-14-2019, 11:10 AM

Why not put it in oven and then properly index sleeve? Unless of course I am missing something else.

Rock

**Gordon02** · 06-14-2019, 05:07 PM

Rock, according to the sleeve guy, the block should have been heated (expanded) and the sleeve left room temperature or less and then pressed in-place with an interference fit (aligned of course). If installed correctly, heating the block with the sleeve in-place as running does, the sleeve expands and will not come out or rotate without some block damage. He recommended boring the sleeve out only and fitting the new/replacement correctly. I have a new, custom make sleeve ordered and should have it before I find a new shop to trust doing the work. Gordon

**Capt.Insane-o** · 06-14-2019, 05:15 PM

I would run the thing before investing another penny in an obsolete block. There is no point in spending another penny. I wish I had pictures of that old xr4. Every sleeve looked like yours and that was untouched from the factory.

**Dave S** · 06-14-2019, 05:17 PM

Fat block? ya mean 2.5 based 2.0? so they are worth something?

**Capt.Insane-o** · 06-14-2019, 05:19 PM

The sleeve was made with larger ports than what the block was cast with. The first couple years of the fat block that weren't 2.5's were sketchy as hell.

**Capt.Insane-o** · 06-14-2019, 05:20 PM

Originally Posted by Dave S

Fat block? ya mean 2.5 based 2.0? so they are worth something?

No, not until some 2.0 f1 sleeves are stuffed in.

**rock** · 06-14-2019, 06:39 PM

I have never even heard of someone trying to sleeve a block without heat. If sleeve is installed without heat how is it installed or should I say secured? I put three in a 90 Merc the other day and screwed one of them up. Not as bad as yours but still it was wrong. Back in the oven and rotated it a bit and good to go. Unless sleeve is cast in place I cannot imagine it not coming loose with heat.

Rock

**Gordon02** · 06-14-2019, 11:18 PM

Guys, the "why" is not what you'd expect. I do this to keep me busy and enjoyment. I need this 2.0L like another hole in my head - in fact, I don't even have a boat for it yet. I've got 2 vintage Chrysler outboard restorations in-process too. I am a busy-body as my friends say. I can't sit still, don't watch TV, and love working with my hands. I like this block because it was free.....I took it's power trim off for the previous owner and installed that into his Skeeter/XR4 and got the complete 135 SeaRay outboard for my trouble. I realized on teardown that is has very few hours and I was going to make it good again. 5 of the cylinders still have the cross-hatching on them. It died an early death because of #6 seizing when the water pump impeller failed. I found pieces of rubber impeller everywhere. So it's not the cost, not the timing - I wanted something to do.

I love collecting and enjoy restoring. My garage got full and the wife said I had to find a new hobby.....Gordon

Right next to the Allison....