3.0 Won't Start After Installing Outdrive/Filling Tank

hoowahfun

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Mercruiser 3.0 and Alpha One Gen 1 Outdrive, motor S/N B515218.

This motor ran with the outdrive removed. Here's what I've done since it last ran:

1) Replaced gimbal bearing and aligned with engine.
2) Replaced all bellows.
3) Replaced impeller and all gaskets, o-rings, etc.
4) Changed the oil in the outdrive.
5) Shift cable is the same as it looked okay and shifted okay before removing. Shift cable re-installed and all adjustments made and seems to work as it should.
6) Trim sending units are currently not installed yet and are just hanging up and out of the way.
7) Trailered it to my local gas station and filled the tank with premium gas. I've since discovered that probably wasn't necessary and could have used regular octane, but I wanted to be safe since I didn't think of it till I was on the way.

After all this, the motor would turn over and ran very rough and would stall unless held at WOT. It never did run right like it did before I put the outdrive back on and filled it up. After about 10 minutes of this it stalled and died and I haven't been able to restart it since then. When I crank it now, it turns over, but won't catch and I start getting some loud puffs out of the carb.

Some other relevant info: The fuel pump, starter, plugs, and plug wires are all new. Oil and oil filter are fresh and new. The motor has run well with all these new items on (when outdrive was off). Has the Pertronix kit on the distributor.

Here's what I've tried so far:
1) Checke the timing probably (visually with harmonic balancer and distributor rotor) 3-4 times.
2) Checked firing order and plug wires 3-4 times.
3) Adjusted throttle cable, idle speed screw, and idle mixture needle per the service manual.
4) Confirmed choke adjustment per manual.
5) Cleaned carb fuel screen. Had a small amount of debris in it, which I cleared out.
6) Checked gas tank vent line. No dips and is free and clear.
7) Checked fuel filter and it was clear and didn't notice anything odd about the fuel in the filter bowl.
8) The carb squirts gas when the throttle is pumped.
9) The plugs are a little wet and smell of gas when I checked.

My battery started to die this evening so I will need to charge that before further testing. Next on my list is to confirm I'm getting spark to each cylinder with my timing light.

Anyone have any other thoughts? Sorry for the large dump of data here, just trying to throw everything out there to give an overall view of what's going on. Thanks!
 

hoowahfun

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sounds like you got a tank of premium water

I sure hope not, but I guess when I get around to checking spark I may have to drain the tank if there's nothing else to check. Why would it suddenly show up now and not when the tank was run almost empty when it was working?
 

hoowahfun

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I didn't see check for actual spark on the list.

That was next on my list, but when I started to go down that route my battery started to drain and struggled to turn the engine over so I called it a day. Will have to recharge it and verify that next. If that checks out I will go down the water in the tank issue unless there's something else I can check.
 

alldodge

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ran very rough and would stall unless held at WOT.

Might just be flooding the motor. Need another with you to see if gas is just pouring out of the carb

To see if its water, disconnect the fuel line from the carb and let it pump some gas in a clear container
 

hoowahfun

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Okay so I finally had a chance to look into this some more. I confirmed that I'm getting spark to all my plugs with a timing light. I also tried to start it off of a remote gas can of fresh fuel and there was no change in the behavior. Still turns over, but won't start and will get some small pops and puffs from the carb. I pulled all the plugs and they were all wet and smelled of gas except for #4 which was dry and a little sooty. I even tried to pour a cap full of fresh fuel into the carb and that didn't help either.

My theories so far:

1) Carb may need to be cleaned. I noticed a couple of dirt pieces on the butterflies and there was gas dripping out one time after I attempted to start it. Maybe it's flooding as AllDodge suggested?
2) Maybe my plug wires are crossfiring? They're pretty close and it's the easiest to check :joyous:

Thoughts?
 

hoowahfun

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Mine is the points system with a Pertronix Ignitor module.

When you say remove the wire, are you saying to check the color of the spark in the plug itself with it removed and grounded to the engine? Will have to look into a spark tester, don't know much about those.
 

alldodge

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Yes, remove the plug wire, insert a small screw drive and hold it close to the block and crack to see the spark

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hoowahfun

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Okay thanks. What color am I looking for out of the spark? Is this better done at night or is daylight okay?
 

hoowahfun

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Spark test showed that all the plugs had a orange/white looking spark. Was kind of hard to tell. It did jump a pretty wide gap fairly well so not sure if that means anything or not. My method was to insert a screw driver bit into the plug boot then hold the boot with pliers and put it near the spark plug end while the motor was cranked. Got zapped a couple of times, must be poorly insulated pliers :)

I also removed the carb last night. I noticed it was dripping again even after I hadn't cranked it for a few minutes which tells me something is keeping the needles from sealing properly. It looked pretty grimy in there anyways so figured it needed to be cleaned and rebuilt. Had a decent amount of debris in the fuel bowl, but haven't noticed any water. I poured it into a jar and will check it this evening to see if any has separated out maybe. At this point I'm thinking it may be flooding the engine and my trip to the gas station stirred something up that clogged a needle seat or something.

Anyone have a good lead on a decent carb rebuild kit? Seen lots on the net that seem to be what I need, just not sure what to really be looking for as far as alcohol resistant gaskets, seals, new float, etc. or if that's even worth it.
 

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TurtleTamer

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Sounds like the float height is way too high (venturi cluster will drip fuel for a while after shutdown), and if there's water in there it can take some time to work its way out. I'd take a fuel sample from the bottom of the tank, too, and see if you can find any water in there. Wouldn't hurt to check compression as well.
 

hoowahfun

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Sep 1, 2016
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So a little update on this issue.

I cleaned and rebuilt the carb and still couldn't get it to start (it needed it anyways so no real loss there). At that point I started thinking maybe there's something going on in the tank since the carb and fuel filters were clean. The check valve was clean as a whistle and moved freely in the fitting. Then I found a little surprise in the 90 degree fitting on top of the tank just before the check valve. Looks like a winged creature got stuck in the inlet screen. Guess it was clogged enough to restrict flow and not allow it to start, but still allow a little gas to go through.

I'm now gonna have to try to pump the tank and filter out any other debris in there. May even try to scope the tank and see if I can tell how bad it is.
 

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alldodge

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Pesky little critters get in thru the vent line many times
 
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