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1996 mercury 150 rebuild

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poopfresh

Member
I am rebuilding my 96 150 outboard and I probably need some help
To begin with, my motor already has a few things missing and some wires snipped. If anyone has the same motor as mine and could take detailed pics, so I can compare and see where things go and connect too, that would be super
Or if there is a manual or something out there, that would help too!
 
After looking at mine. I have the plug like yours that has the white, black, and blue wires on it. Mine, however hooks up to my oil pump assembly. Mine is fuel injected, and mixes its own oil. Yours looks carbed.
 
I’m assuming the wires are snipped there because that bracket is supposed to go to an oil pump. Since yours is carbed and doesn’t have an oil pump I’d say they capped that off since it’s not needed, and cut the wires also. I can’t find anything like that in a parts diagram on your engine.
 
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I see the one head is loose and bolts are out.------The wise thing would be to take this thing apart.----Evaluate the cost of rebuilding.----Worry about the wires when you have decided it is worth your time and in your budget.
 
One cylinder had low compression, so I took the head off. Cylinder wall has some score marks so I plan on resleeving that cylinder and put new piston rings. Should I put new rings on all pistons or just that one?
 
Determine the cause of that scoring.----Otherwise the rebuild will not last long.----Measure / inspect all parts when you have it torn down.
 
Previous owner said it over heated but he caught it on pretty quick, at first he thought it was lower unit not pumping water. So he rebuilt impeller, later to find that it didn't help, thats when compression test was done to find that one cylinder down.....I plan on having machine shop inspect piston and components
 
Need to really check out fuel and ignition system, That damage is NOT lack of water and same problem may have happened before as the two cylinders in pictures are bored .020 oversize.
 
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Does anyone know where I can find torque specs for block etc.... having someone bore out cylinders. He should be done in next week or so
 
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