The Mercury 2.4-liter V6 Cylinder Head Gasket is designed for early-generation Mercury V6 two-stroke Mercury 200 HP and 225 HP 2.4-liter outboards produced between approximately 1978 and 1982.
These engines were among the first high-performance 2.4 Liter V6 outboards from Mercury Marine and were widely installed on bass boats, offshore fishing boats, and performance hulls during the early years of Mercury’s V6 platform.
This gasket seals the mating surface between the cylinder head and the block, maintaining combustion pressure while isolating cooling water passages. Proper sealing at this interface is essential to maintain compression, cooling system integrity, and long-term reliability in these classic Mercury V6 powerheads.
Buckshot Racing #77 supplies replacement cylinder head gaskets that match the early fitment and sealing characteristics used on these early bolt-pattern Mercury Marine and Mercury Racing 2.4L V6 engines.
Unique Early Mercury 2.4L Block Design
Early Mercury 2.4-liter V6 engines used a distinctive block construction that differs from later V6 Mercury designs. On these engines, the cylinder head bolt holes were cast into the outer diameter (OD) of the cylinder sleeves in the water cavity vs into the aluminum block itself.
This engineering approach was used on many early 3.375-inch bore 2.4-liter blocks, particularly those produced from 1978 through the early 1980s. Because the head bolt bosses are part of the sleeve structure, the cylinder head gasket must align precisely with both the sleeve bolt locations and the surrounding cooling passages.
Engine Fitment and Applications
This cylinder head gasket fits early Mercury 2.4L V6 two-stroke outboards, most commonly including: Mercury 200 HP 2.4-liter V6 (approximately 1978–1982) and the early 7-petal Mercury 225 HP 2.4-liter V6 (approximately 1980–1981)
These engines were frequently sold under the Mercury Black Max product line, and they became the foundation for many of Mercury’s later high-performance V6 outboard designs.
Typical applications include bass boats, performance lake boats, offshore fishing boats, and vintage Mercury performance builds. Many of these engines remain in service today due to their durability and strong performance characteristics.
Cylinder Head Gasket Function
The cylinder head gasket performs several critical functions in the Mercury V6 engine architecture. It seals the combustion chamber to maintain cylinder compression, prevents combustion gases from entering the cooling system, and isolates cooling water passages from the combustion chamber.
During operation, combustion pressures inside a Mercury 2.4L V6 outboard can exceed several hundred PSI. The gasket must withstand these pressures while also tolerating repeated thermal expansion cycles and exposure to cooling water.
A properly installed gasket ensures stable combustion sealing, balanced cylinder compression, and proper engine cooling.
Common Mercury and Aftermarket Part Numbers
This cylinder head gasket is referenced by multiple Mercury OEM and aftermarket numbers used in marine service catalogs and parts databases.
Common Mercury references include: 41244, 41244T02, 41245, 412451, 412452, 77671, 90279, and 96541 that are no longer available from Mercury. These numbers help identify compatible replacement gaskets when servicing early Mercury 2.4-liter V6 outboards.
Service and Installation Considerations
Whenever the cylinder heads are removed on a Mercury 2.4-liter V6 powerhead, the head gaskets should always be replaced. Heat cycles and combustion pressure compress gasket material over time, reducing its ability to maintain a reliable seal.
During reassembly, both the cylinder head and block mating surfaces should be thoroughly cleaned and inspected for flatness. Proper torque sequence and torque values must also be followed when tightening the head bolts to ensure even clamping pressure across the gasket.
Installing fresh cylinder head gaskets during service helps prevent compression loss, cooling system leaks, and overheating issues.
Supporting Classic Mercury V6 Outboards
The early Mercury 2.4-liter V6 platform, particularly the 200 HP and 225 HP engines produced between 1978 and 1982, represents an important chapter in Mercury’s high-performance outboard history. These engines laid the groundwork for later Mercury Racing designs and remain popular today among restorers, performance boaters, and vintage outboard enthusiasts.
At Buckshot Racing #77, we support the continued operation and restoration of legacy Mercury engines by providing proven replacement parts for classic two-stroke outboards.
Whether maintaining a vintage Mercury 200 HP 2.4L V6 or restoring a classic 225 HP Black Max, installing the correct cylinder head gasket ensures proper combustion sealing, reliable cooling system operation, and dependable performance on the water.
Contact Mike at 714-697-1716 or mike@buckshotracing77.com for technical support.