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Thread: 2002 200xs

  1. #16
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    Brilliant, thanks PanRonnie

    Its just a super lightweight one piece adapter and not rocket science.
    The only question it raises is whether to vent/ drain the dump cavity to atmosphere as the photo shows(into the leg) or vent/ balance the cooling system back down through the main water infeed gallery as is done with a two piece adapter the answer to that question simply determines the position of that 1/8 hole in the pan plate.
    The hole as shown in the specs you've posted will increase water flow though the motor as it vents continuously to atmosphere whereas the equivalent hole in the 2 piece system doesn't promote flow because it is a port with approx equal pressure at both ends.
    My idea might be to do the 2 piece equivalent first using just the hole into the water duct then if that doesn't work drill a random 1/8 hole as in the pic.
    Im trying to work out the engineers thinking was and it may be to do with the gasket.
    That 1/8 hole is through an existing hole in a stock gasket.
    If the hole was put in the center into the main infeed water gallery to mimic the 2 piece it would require a modified gasket which would lead to many disasters down the track.

  2. #17
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    if you mean that little hole next to the poppet valve dump!? i think that is there to drain the water that would otherwise be left there because the poppet valve hole is higher than the base plate and water could remain there and possible freeze i guess

    dont think this is a big problem or they where wurried about electrolytic corrosion between the stainless steel and the aluminium of the block

  3. #18
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    It may be a multi purpose hole.
    Its probably possible to get an airlock in that cavity also as I think the roof of that cavity in the engine block might be above the drain holes in the heads that feed that cavity.(Ill check that tomorrow).
    Also note that the plate has two 3/8 holes in the shallow dump cavity, one on each side of the plate.
    This indicates to me that one of the functions of that little hole is to flow water to both sides of the plate and into the leg, possibly to help cool the tuner.
    If that little hole was just a drain then why not have just one 3/8 hole or even one 1/4 hole or for that matter why even have that shallow cavity at all.
    I reckon that shallow cavity is actually intended to flow water across to the second 3/8 hole.
    The guys that have had the stretched pan plates probably wouldn't have had that issue had they had that little hole.

    That 200xs plate is just a squashed one piece with a poppet dump gallery of standard size that maximizes flow.

  4. #19
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    Quote Originally Posted by NZ Sidewinder View Post
    Did you note what the difference was in layout that made it work.
    I did and made a sketch of it but that was a long time ago. It was different then 260 and 280 plates. Would have to find sketch to give exact differences.

    One difference was it shifted the cowl to the rear giving clearance for the air pump and fuel rails on the heads. Must be a really tight fit to get the cowl on with a 200XS powerhead and a 280 Stainless plate.

  5. #20
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    It would be great to see the sketch and it could possibly save some engines.
    As I see it the worst heat has been at No 6 which of course is the nearest the pan.
    This suggests that the heat source is the cylinder which may be stating the obvious.
    If it were my engine Id be thinking that the bent pan plate was the least of my problems.

  6. #21
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    You also want to make sure the diverters are in
    As they route the water around the cylinder walls when it comes in from the exhaust cover
    Otherwise water will take the shortest route leaving the outside of cylinders 5 and 6 to higher temperatures39 and 40
    Attached Thumbnails Attached Thumbnails mercury_200_SST_diverters-1.png  
    Last edited by PanRonnie; 09-19-2021 at 08:45 PM.

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  8. #22
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    Did a bit of research today and got some better info. This Allison did originally have a 280 and it did puke a couple times and powerhead was replaced under warranty. On the last failure the owner told the dealer he did not want another 280 as they were not working out so well and asked to change to a 200xs. Dealer got mother Merc to exchange 280 with the current 200xs. I was wrong stating it was a 2002 when it is actually a 2001 which is the same as mine. When the swap was made it was a complete motor exchange so it was in fact a 200xs on a 15" offshore mid. Makes sense cuz cowl plate accommodates the necessary hoses and 1 piece adapter has water strainer for the compressor supply and dump fitting. Hard to remember what took place 20 years ago. Anyway new plate is on its way and I will post how well it fits. Mercury lists it a NLA.

    Rock
    Team Junk

    No sparkling wiggles in here, only dump truck grinches.

    "Screamin Heathen"

  9. #23
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    “Hard to remember what took place 20 years ago.”

    Man ain’t that the truth! Then you start second guessing yourself and your memory.

  10. #24
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    Wow, never ever knew Merc offered a 200XS 15" factory in the first year of production.

  11. #25
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    Found tracing of the 200xs lower cowl stainless plate. Pretty light but look close you should be able to make it out. Click image for larger version. 

Name:	4898AEB8-048F-444D-963A-354882DB46F5.jpg 
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  12. #26
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    Something like this one

    Click image for larger version. 

Name:	new pan plate and tuner.jpg 
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  13. #27
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    Something like it but not the same.
    Don't think it will work if you’re going to use it on a 200XS.
    The 200XS with the compressor and fuel rails on the heads needs the cowl shifted back to give clearance for those components.
    Don’t see the small hole which is probably just for drainage.

  14. #28
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    This one is for a steel sleeve promax.
    The system mimicks a two piece.
    I've not put the drain hole in the laser cut file because there are a few options for it so can be drilled.
    I've got 4 of these pan plates so by drilling as required I can change design without altering the cutting file.
    To be an exact water route duplicate of a two piece then the drain hole goes through the pan plate into the main water intake duct.
    This is something that is doable but has fine tolerances.
    It's also difficult to explain as well as to understand why the two piece has it perched up on the casting so that it doesn't fully drain the cavity.
    It could have been in the floor of the cavity and draining into the eyebrow ducts.
    So on this basis I've decided that best practice is to copy the 2 piece placement of the drain hole just in case there is some special reason it is done like it is.
    So for te first pan plate it will have a sneaky little hole that I'll show in a pic when done
    Last edited by NZ Sidewinder; 10-18-2021 at 05:40 PM.

  15. #29
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    Hi Onetime
    Do you have a measurement that the pan has been shifted rearward.
    Ive scaled it from your tracing and the number comes out at 2.81 inches or 71.5mm.
    It so happens that I have a credit at the laser cutting shop thats needs to be used so Ill get a couple cut.
    If anyone wants a copy of these .DXF files just sing out.
    Best practice is to get a gasket cutting outfit to cut files in cheap paper first to check fit.
    These ones all match the original parts really well.
    They may come in handy Click image for larger version. 

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