A few tips on the 2.5l EFI rebuild...
So it begins...With the arrival of the 1994 used 2.5l Mercury powerhead, I began to disassemble the 2000 powerhead. I cant stress enough how important it is to take dozens if photos of the block as you remove each item! Label each wire and hose as you disconnect them. The 94 powerhead is almost identical as the 00' with a few easy modifications.
I called around to many shops, the prices ranged from $6000+ for a new crate powerhead (minus all the bolt on's) To $3500+ to have the power head #2 cylinder re-sleeved and welded & crank polished. Not having any luck finding any used '00 powerheads, I located a decent used '94 in Florida and bought it for $380 shipping included! (upper, lower block & crank). The parts needed to complete this task are; #2 piston, connecting rod, piston ring kit, #2 rod bearings, crank bearings, crank rings, #2 reed valve & engine gasket kit. The crank will be sent to Harrys Machine in Northborough to have the #2 journal polished.
At first I was told that the engine was believed to be fine, that the only repair required was in the jet drive... Then after close inspection, I determined that the engine was blown, not the jet drive. I figured the engine failed due to overheating caused by no water being circulated through the powerhead due to the boat being run while beached... However, upon disassembling the block, I found the reason the engine failed was due to a damaged oil pump gear on the crank **see photo** which in turn caused the engine to run on straight gasoline which caused the #2 cylinder to fail. (Makes you wonder if the convenience of having an oil pump is worth it...I think I'd rather premix the oil & gas and bypass the pump just to make sure this wont happen again!)
With a little patience, creativity & balls, I plan on saving thousands of $$ doing this rebuild myself. At the end of it all, I plan on having a $13,000 20' Challenger for only $4500 (and that includes the purchase of the boat!)
*** Please bare with me in regards to the proper names of each item, I have ordered the shop manual but have yet to receive it. Corrections will be made as the project continues.***