200 Efi

[CLAYC]

01 200 EFI... Here's the problem.. 3 months ago engine would stall at WOT then wouldn't build RPM above 5000. While on dyno, broke #5 piston. Piston has a crack below the wrist-pin, which appears to have been there awhile. Piston hung ring causing the damage. Had to re-sleeve #5 do to a crack.

New piston and sleeve, with rebuild, engine will free rev but will stall/shut down at 2500 RPM while on dyno. Engine starts easily and sounds great... Have changed or rebuilt: stator, injection fuel pump, pulse pump, cleaned/ o-ringed injectors, ECM, Trigger, changed out CDM's, TPI, checked all wiring (hull and engine harness), Injector contol module, and the reeds were checked upon reassembly.

Still having same problem.. Merc tech in my area is as stumped as I am... Next stop is a call to Mercury... If anyone has any suggestions, PLEASE DO SO.... This has already cost me two tournaments and several weeks on the water.

 

[CLAYC]

Re: 200 Efi

and all cylinders compression test at 140-145 psi....

 

[Faztbullet]

Re: 200 Efi

Double check that the butterflys are opening fully at WOT cable position.Also check the tpi setting, if yours is a 2.5 liter the factory specs are .200 through .300 volts with .250 being the factorys idea of perfect. .250 is where they set them when they were built.

 

[Ed R]

Re: 200 Efi

I feel for ya, i troubleshoot these motors every day! first i wuld go back to the basics. compression, fuel, and spark that the right time. fuel pressure, tpi, syic/link set up etc..... 01 ign system was new on some models that year . Do you have switch boxes or ECMs What plugs are you useing?? what temp is the motor running at?

 

[CharlieB]

Re: 200 Efi

T a vacuum gauge into the fuel line before the pulse pump, want to see if there is a restriction in the fuel feed line caused by a too tight zip tie hidden by the wiring/hose cover.

Clean and tighten all grounds ECM/injectors/battery. Check temps of all wires and connections as the fault occurs