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Author Topic:   Repairs to 1982 Merc 40 2 stroke
JimU posted 10-03-2001 04:44 PM ET (US)   Profile for JimU   Send Email to JimU  
I have an old Merc 40 2 cyl that I got in a boat deal. The engine runs fine. One problem. After replacing the water pump my mechanic said the water jacket in the block is corroded and plugged up. At $55 per hour he said it would take about about 8 hours of labor to tear it down and clear the corrosion and unplug the system. Any experience out there for do-it-yourselfers. the engine is not too complicated and I'm pretty handy. Any advice? Thanks, JIM
Bigshot posted 10-03-2001 04:55 PM ET (US)     Profile for Bigshot  Send Email to Bigshot     
Have you run it yet? If so is it pumping water?
andygere posted 10-04-2001 01:56 PM ET (US)     Profile for andygere  Send Email to andygere     
I had a mid 80's Merc 40 on my 13 and it was a real dog. There are lots of these motors for sale as "parts only" so you may be able to find one with a decent power head and swap it. Mine suffered from ignition problems, internal shift linkage issues and blown head gaskets. Over it's lifetime, I pumped a lot more money into that motor than it was worth, so be careful. You may just want to put a temp guage on it and run it as is. Actual value is probably less than nil, but as we all know, new outboards are not cheap!
Bigshot posted 10-04-2001 05:16 PM ET (US)     Profile for Bigshot  Send Email to Bigshot     
Reason I ask is if there is not a TOTAL clog, I can't see how he could estimate that cost. could be as simple as a thermostat or just blowing air through the peehole to clear it out.
Clark Roberts posted 10-04-2001 09:50 PM ET (US)     Profile for Clark Roberts  Send Email to Clark Roberts     
Jim, it's not a pleasant job but it's a no-brainer and you certainly can do it yourself!Here's my suggestion: remove the water jacket cover (it looks like a removable head but it's not as these Mercs are blind bore and have no detachable heads).. take out all the perimeter bolts carefully and the cover come off leaving the two spark plugs screwed in the top of cyl casting... now you can see down all sides of each cyl and spoon or other wise remove the offending material.. once all is removed you can use high press water to finish the job... hopefully this will solve problem (worth a try). If still cloged then the clog may be located in the laberenth area between power head and mid section.. requires power head removal to clean... still not a terrible job providing head comes off and no bolts are broken off.. feel free to e-mail me... if you know someone who has done this and will help out.. go for it.. Good luck,, clark.. Spruce Creek Navy

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