Engine rebuild, please help!

[fierodough]

Engine:
1997 Mercury Sport Jet 175HP XR2
Starting serial numbers: OE272

3 cylinders have the rings seized to the pistons resulting in very poor compression.

I pulled the engine and started taking it apart. I am now down to the crank and ran in to a new problem that I will need some guidance with.

The oil injection pump drive gear is stripped, the driver rod is seized, the black bushing that the external pump attaches to will NOT spin and I assume this should spin freely. I have a shop manual but it is not very good. It discusses the external components of the oil pump but does not address how to remove the seized bushing and how to install a new one.

Also, one of the crank shaft compression rings was snapped or somehow snapped when I split the block (crank cover).

Where can I find a parts list or a parts diagram?

Also, when I took readings of my cylinder bores, my lowest value for one cylinder is 3.479" (4 reading per cylinder, 2 top and 2 at bottom at 90*) but my shop manual says the standard bore when new would of been 3.501.. My cylinders got smaller??

Thanks in advance for any help!

 

[racerone]

I think there was a factory recall on those at one time.---There have been issues with that plastic drive gear in sport jet operation.-----Seems people with those machines are always on the throttle and off again , on and off again.

 

[fierodough]

No Title

Ok, I found a parts diagram showing some of the parts that needs attention.

http://www.potomacmarine.com/pages/...omponents/13-002-835085R|~2-270/COMMON9011409


The failure point of my oil injection system seems to be:

#15

41429A2

BEARING ASSEMBLY, Drive Gear

How do I drive the bearing out?

What is involved in disabling the oil injection system and simply premix 40:1? I want to keep my overheat alarm but disable the oil injection alarm.

 

[fierodough]

Bump!

 

[fierodough]

For me reference, complete gasket set: http://shop.tsmperformance.net/Gasket-Kit-Mercury-Sport-Jet-175hp-Replaces27-850396A1-TS-500-221.htm Part number: 850396A1