Another Merc 240efi rebuild

[njrealtor55]

Traded my Seadoo jetskis for a 2001 Seadoo C2k with low compression in 1 cylinder. Got it home before the Holidays, and finally had time to pull the engine. Getting the engine out was fairly easy - next step is pulling the heads to see the damage.

 

[njrealtor55]

decided to buy a complete reman engine from Crowley Marine. Had to replace the reeds (no chips, but they wouldn't stay closed) so I installed Chris Carson Reeds (http://www.chriscarsonmarine.com/reed-valves.htm). Had to drill out a bunch of the OEM screws that hold the reeds to the cages - but once the head is drilled out the threaded portion comes right out. Carson Reeds also sold me a complete set of screws for all the reeds as well.

My throttle body looked like it had sat at the bottom of an oil drum for 30 years. I had Brucato perform a complete Fuel Injection & throttle body cleaning/service (http://www.brucatofis.com). Brucato was good, they found that the injectors were not all flowing at the correct rates - and adjusted (4) of them. They also cleaned the entire throttle body - you can eat off it now.

My VST tank was a mess, and I luckily was able to get the soft OEM screws out w/out drilling. Ordered new stainless screws for the VST (went with allen heads) and replaced the high pressure fuel pump filter too. Got the engine in 2 days ago, and siphoned all the old gas out last night. Hope to fire it up Saturday morning, and dare I suggest a trip to the water directly after?

I'm sure something else will pop up, but this was an interesting experience. Much more involved than a Seadoo 787 or 951 engine replacement. The hardest part was remembering how everything was wired/routed. I took a bunch of photos, but as expected there was no photo for the areas I needed help in (and the manual was vague).

Next up, initial fire-up and water test. I will report back soon, and try to post some more pics.

 

[njrealtor55]

UPDATE:

Engine fired up perfectly & sounds great. Unfortunately the gasket between the block and the exhaust support plate is not sealing and I have a major water leak out of the bottom of the engine. I was really aggravated when I saw the leak on Saturday...

So, new gaskets are on order, and the engine is going to have to come back out. This time I will use some 1211 on the mating surfaces to guarantee it seals.

Since I couldn't drive the boat Saturday, we decided to clean it instead.

Here is the link to the online pics.
https://goo.gl/photos/rXUcFhHb4KXjSnLj9

 

[njrealtor55]

update:

turns out the pump support gasket was ok - i never installed the large plug on the exhaust cover plate. oh well, live and learn. I now have about 3 hours on the new engine. Boat runs good so far - seems a little slower than my brother in laws (he has a 2001 Challenger). Still no full throttle, but it really likes to cruise around 4500rpm.

I need to service the pump, and replace the impeller - so hopefully a Solas impeller and new stainless wear ring from impros will get me some additional speed. Also need to check fuel pressure and timing eventually.

Family loves the boat - it was a great buy.