Remanufactured 240 EFI Engine

[jsartain]

I have not posted much on this forum, but I would really appreciate any help. I have a 2002 Challenger 1800 with the Mercury 240 EFI engine. I lost power at the end of last season, so I started this winter to determine the problem. When going through the engine, I found that flywheel failed into the stator. I replaced these parts along with the trigger and everything worked fine (for about 10 minutes). Then I had the same failure occur. I took the flywheel off and grabbed the cranck, which moved.

Bad news. I did not have time to rebuild the engine, so I hired a certified mechanic to tear apart the engine to determine the entire problem. Of coarse the crank seal failed, which caused lots of cylinder damage. I was informed that it would take be about $5k to rebuild the engine. This seems fair, but I would like to see how much a remanufactured engine would cost. The rebuild will not be warranted is also a problem. I am planning on selling the boat so I can upgrade, but I need a running engine to sell it for anything decent.

I do not have any contacts to get a remanufactured engine to determine if this is the direction to go with the boat. Does anyone have any thoughts on my situation?

Thanks in advance for the help.

 

[Big Dog]

Sounds like that is about $2,000 to high from what I have read on this forum. The guys that did their own rebuild spent about $1,500 on parts. If the mechanic gets $1,500 for labor I would think that is fair. Rebuild cost should be about $3,000 if your block is OK.

 

[LouDoo]

I did a little research and this is kind of a strange (at least to me) beast. It appears that what you have is an outboard power head mounted on a jet pump.

I couldn't find anyone who remanufactures these. I know Jasper remans marine engines, it might not hurt to call them, if they can't maybe they could refer you to someone who can.

If not I guess you are going to be at the mercy of a Mercury dealer or mechanic, as I think parts are going to be a problem.

Lou

 

[Double07]

I agree with Big Dog. 5K sounds a bit much for a rebuild, especially if you are not getting any waranty with it. If you had the time, you could save yourself a lot of money. I would suggest a rebuild by yourself if possible.

-Chika

 

[ddeem]

The $5K seems too high for a rebuild unless the block is ruined. I have a thread on ths forum that I rebuilt the entire motor with .030 pistons for $1,100 in parts and $300 machine work. Did the motor myself so no labor charges. Unless the block is ruined, I would agree with some others that $3K would be a fair price. Maybe a few hundred more if they are pulling and installing the motor.

 

[jsartain]

I appreciate all the advice. I think that the $5k could be a little high, but maybe a little in line knowning that I have to replace the flywheel and stator again (which cost me almost 1K) the first round. I am still weighing out the situation.

The good news is that I now have a contact out of Stillwater, OK that sells parts for this engine. This company is made up of previous Mercury Marine engineers when Mercury was producing engines in Oklahoma (up to a couple years ago). Their price for a remanufactured powerhead was $4200. I know that this is going through a second party and not directly from Mercury Marine, so it has an additional margin on the engine, but it seems close to correct from what everyone is stating.

If anyone needs the contact to parts, please let me know. I am sure most of you know the company already and I don't want to petal products on forums.

 

[LouDoo]

Sorry wrong thread.

 

[seadoodude1]

$3990 at http://www.crowleymarine.com/powerheads/mercury_mariner/200_220hp.cfm

I have wondered if it is possible to put a 4 stroke power head on instead???

 

[todd09]

Last year I bought the remanufactured 240EFI from crowleymarine and in total it cost me just under $5000 to repair. However, I bought the boat for $500.00 used knowing the engine had blown so I had a few other things that I needed to to to get it up and running including having the fuel rails checked, the MANUAL(VERY HELPFUL), battery, rock grate, and a piece of mind timing check at the marina. Some other things went into the cost as well such as not getting a full powerhead core refund since my old powerhead had some undesirable holes in it from where the piston rod smashed throught the side! . Crowley Marine was very helpful and was able to answer a lot of my "stupid" questions as I didn't know a lot going into the project.

 

[WAJetboating]

I did a little research and this is kind of a strange (at least to me) beast. It appears that what you have is an outboard power head mounted on a jet pump.

That's exactly what the SportJet is. A very standard, very common 2.5L V6 Mercury two stroke engine (or 3.0L for the OptiMax 250). It happens to be sitting on a jetdrive instead of an outboard lower end. Otherwise, it will look very familiar to anyone who works on Mercury outboards. It shares parts with outboards, tools and service procedures with outboards, etc.

Someone else here has already mentioned Crowley's, and I have seen others (names escape me right now). But really, anyone who works on large Mercury outboards can work on a SportJet.