Mercury 200 EFI rough idle and small loss of top speed

killerpiraat

Recruit
Joined
May 5, 2022
Messages
2
Hello,

Sorry that my first post here is a question :)

I own a 2.5L 200 EFI (1996( since a year and it has run really great.
2 weeks ago it started to idle very rough. Shaking and not willing to keep running at idle in gear. When i give it the smalles amount of throttle, it runs fine and at all other RPM's the motor feels very strong.
Also, it seems like i have lost some top speed 5 kmh (from 121 kmh to 116 kmh).

Normally i would be able to understand the issues and fix them myself, but this one is a miracle to me.

What i have done so far:
-Comression tested (all are 90 psi, except #5, which has 85 psi. I tested with harbor freight
tester, so consistency is what i am looking at)
-Swapped ECU with an older 175 XRi ECU i have laying around. it idled better then before, but still not very good. Sometimes it idles rough, sometimes it sounds ok on the hose.
Swapped the 200 ECU back, suddenly it idles the same as with the 175 ECU.
-Visually inspected cylinders with camera, nothing special to see
-Rebuild mechanical fuel pump
-Inspected VST
-Tested injectors on my bench
-Tested fuel pressure (35psi on all rpm's)
-Inspected reeds & replaced them with Boyensen reeds (carbon)
-Tested spark by holding plug to block. All 6 cylinders have spark. Also tested this with timing light, it flashes on each plug when running.
- Removed spark plug wires from plug while engine is running. When i disconnect the ENTIRE left bank, nothing happens to the idle. It stays idling the same, running on 3 cylinders. It seems to idle ok. When i disconnect even 1 plug on the right bank, it starts idling like sh*t immediatly.
-Disconnected idle stabilizer, no change in both timing or RPM.
-Swapped 1 switch box (the one for the left bank)
When you reconnect a spark plug wire on the left bank, you can hear a very small bump in rpm, but then returns to previous RPM.

I have no idea what could be causing this. Stator maybe?
 

Dukedog

Captain
Joined
Oct 6, 2009
Messages
3,439
start with TPS (good chance this is tha problem)... also tha temp sensor on port head....
 

Dukedog

Captain
Joined
Oct 6, 2009
Messages
3,439
before we got tha harness we use a coupla needles inserted into tha wire itself... think its between tha tan/? and orange???.. long time ago, not positive on those colors.. sure someone else on here will know that for sure...
 
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