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2001 200 EFI RPM issue

C

charlesrowell

New member
"Hi all. 200 merc with RPM pro

"Hi all. 200 merc with RPM problem. Oil level got low on me and no alarm came in(alarm fixed), but still can not get up over 22-2300 RPMs. I hear a minor noise that sounds like mechanical failure, but before i tare the motor apart, does anyone have any other ideas, while running the day of low oil level, the motor started shutting down (i am assuming to protect itself). Is there something that needs to be RESET for this problem to go away?"
 
"Charles, could you post your

"Charles, could you post your serial number. I ask because, if you are off in your "year" by one year either way, the components in your motor will be drastically different.

Between 2000-2002, Merc introduced the ECM on their big EFI's. If yours is in fact an 01 model it will have a CM or Control Module. It was used on both carburated and EFI models.

The CM is described by Merc as follows:

The control module provides rev-limit (carb models), bias control, shift stabilizer, idle stabilizer, injector timing signal (EFI models), and low oil warning.

So, if as you state, that you got no alarm and your rpm's are restricted, you could have a bad control module - or alternately, it could have failed, which led to no oil alarm and a low oil condition actually damaged the engine."
 
"The alarm is working now, but

"The alarm is working now, but there is still something holding the RPMS down. When the motor started shutting down from 55K to less than 25K while in operation i knew i had a problem, LOW OIL turned out to be the cause. i was close to the boat launch so i idled in and shut down immediately, added oil at the launch, and tried to run again, would not get up over 2300RPM. Serial Number is 0T306291 Model# is 1200123YD"
 
"Charles, I have had a read an

"Charles, I have had a read and the best I can determine is, if your revs are being limited by the ignition system, it will be the Control Module (CM) that is responsible.

In the design of this ignition system there is no sensor that you can simply "un-plug" to see if it is the issue.

Perhaps if you can get ahold of "Bandit", or if he sees this post, he can give you a troubleshooting option. From what I have read, this module can not be easily tested "at home"...."
 
"It is just bothering me ,most

"It is just bothering me ,most places here want 50/hr to look at it. Just trying to get some ideas before i bring it to the shop. Just beyond me whats wrong with it, the motor didn't ever do this until the oil level ran low. Could the CM still be the issue, i dont know much about electronic stuff. I have ordered a manual off this site, hopefully i can get some ideas from it also."
 
"You spoke of a minor noise or

"You spoke of a minor noise or mechanical failure, put a timing light on each plug wire and check for spark, or remove the plugs and look at them. I know this will not fix anything but if a plug is fouled by metal then at least you know what needs to be done."
 
"Pulled the Top Right plug out

"Pulled the Top Right plug out, DISASTER. The Piston is in PIECES. or Whatever is inside the head is in PIECES. So can i fix this myself, i have rebuilt several car engines? What can I hurt by doing it myself? Electronic Wise? I am going to wait on my manual to get here before i start taring down!"
 
"I'm sorry for your loss.

"I'm sorry for your loss. This is a high dollar repair, best left to someone willing to stand by there work. I would hate to see you invest in the repair only to have the timing set wrong or a sensor fail and ruin the engine."
 
"You and I don't even know

"You and I don't even know what happened.
Did the piston fail, did the rod break, did it tear up the block. What caused this to happen, did the computer fail, or was it simply out of oil. How many pistons and how much machine work.

That being said, I don't work on these for a living. I would not even have a guess. I might consider finding a shop that has power heads built and ready to go if you need the boat. Do you have the funds for a new power package? Some owners won't trust that engine again even if it is rebuilt."
 
"I pulled the heads off ,looks

"I pulled the heads off ,looks like it is just the Number 1 Piston that failed due to lack of oil (as stated earlier), no alarm previous to engine shutting down. It looks like its a New Piston, New Rod, New Bearing, and New Sleve, the Block itself looks to be ok compared to other pistons."
 
"I wish you well, but if that

"I wish you well, but if that ran out of oil there has to be more damage. I would think some bearings and some rings would be damaged. Usually the piston would seeze do to lack of oil, the rings would be stuck/welded to the cyl. Piston failure is caused by detonation. I wonder if it was the oil of the computer. Was it really out of oil?"
 
"Yes , was running about 5500

"Yes , was running about 5500 RPM when the motor started shutting down, RPM dropped to about 22-2300. I never got the alarm (little did i know the annouciator was out), but yes, it ran low on oil."
 
If the piston is in 1000 piece

If the piston is in 1000 pieces than oil is not the issue here. Detonation is what happened. If this is a T-Bolt ign. than I would replace the stator an sw. boxes during the rebuild.
 
"Hmmm, what a mess - even if y

"Hmmm, what a mess - even if you can get away with having the cylinder honed, or even rebored slightly - no sleeves on these babies - which most shops will do for 50 bucks or so, a piston, rod, and rings will run you near 600 bucks (from Merc anyhow) - and that's assuming that the bearings survived.

If you feel comfortable doing the work, you could grab a factory service manual and have a nice winter project. Otherwise, I would take JB's advice and maybe either look for a rebuilt head, or dig out your wallet and find a good shop."
 
"Does not look like the block

"Does not look like the block is damaged, and if this thing doesn't have sleves, then i'm not sure what i pulled out that was enclosing the piston (wrapped around the inside of cyclinder wall). The head cover itself looks like it has been hit with a ballpen hammer by a 3 year old a few times, i'll get a new one of those."
 
"very likely the rod bearing d

"very likely the rod bearing damaged by lack of lube. this would take out crank too. if you are thinking of rebuilding yourself, tear down first to assess damage before ordering parts."
 
"I shined a light through the

"I shined a light through the 1 1/2 inch hole in the number 1 piston. Looks like the internal damage is not to bad, but this will have to be assessed once i get the motor apart. I will wait for the ordered manual to come in before i venture futhur. I have a couple of contacts that i will be getting with on Monday to see if they can stop by the house and take a look as well. I would like to thank everyone for their help and i'll keep you all updated. This is a great site, not sure how i came across it, but its worth while."
 
O.K. More info on the ign. Th

O.K. More info on the ign. The CM. ign has the CD bias inside if it. The module must get replaced. Once you get it apart you can tell exactly what happened. Start by getting the P/H off. Lack of oil will show up as a build up of metal on the walls.
 
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