Need help 94 Mercruiser 305

Bry21317

Chief Petty Officer
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Apr 9, 2002
Messages
552
Ok,
I met the mechanic out at the lake today and took the boat for a spin. Well it runs ok, but it is overheating for some reason. I need some help to figure out what it might be. I had put a 142 thermostat in it. This is also the first run since the Upgrade on the Carb and the New Air gap Intake. We checked the impeller and it was good, he had also replaced this. This is what we thought it was, but it was not this. We then checked the output to the Thermostat housing from the impeller hose, and it was good also. We then pulled the Thermostat out and tried with no thermostat in it, and it still overheats.

At higher speed it was not as bad, the temp would fall down to or below 175 on the guage, but at slower speeds it would climb up to 220 +. The lake water was pretty cold to, I would say in the 50s, so that should have helped cool it.

The only thing that he can think of is that on the new manifold, there are two water plugs at the very back of the intake, and he thinks it might need a hose between these two holes to allow the water to both sides of the intake manifold.

Before this engine would never go above 165ish, on the gauge, so I am worried now as to what would cause it to overheat.

Also, with the 4bbl upgrade and the Labbed Rev 4 Prop, I still had the same Results on my speed and topend RPMS. The mechanic drove the boat, but it still comes up and out of the water very quick and midrange seemed better for sure, even though it had no real lag.

Does anyone have any ideas as to what might be causing it to overheat? Also there is alot of soot building up now around the thru hull exhaust. He said he has the carb as lean as it can go, and its still running rich. He checked the timing also and put a fuel pressure regulator on the fuel line and its set at 3lbs psi.

Thanks for any input and sorry this is so long. By the way the lake was awesome today, and its nice to see it almost up to Full.

Bryan
 

John_S

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Re: Need help 94 Mercruiser 305

"The only thing that he can think of is that on the new manifold, there are two water plugs at the very back of the intake, and he thinks it might need a hose between these two holes to allow the water to both sides of the intake manifold. "

The manifold you removed had them blocked, didn't it?


"Also there is alot of soot building up now around the thru hull exhaust. He said he has the carb as lean as it can go, and its still running rich. He checked the timing also and put a fuel pressure regulator on the fuel line and its set at 3lbs psi."

He needs to look at the float/needle/seat to see why it is not stopping the fuel. Remove the regulator. It is a poor bandaid.


"Does anyone have any ideas as to what might be causing it to overheat? "

Partially crimped inlet hose, air bubbles from bad raw water housing/impeller.

What type of thermo housing do you have? 4 or 6 hose? Did you change this with your intake replacement.


"Also, with the 4bbl upgrade and the Labbed Rev 4 Prop, I still had the same Results on my speed and topend RPMS."

What rpms and mph? Is this the prop you ran before the intake change?

PS: It might be better to keep everything in one thread. Most people won't search to find the prior threads.
 

firehog6305

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Re: Need help 94 Mercruiser 305

I'm sorry if I missed it on your post, but did you mention the impeller, or the water pump??
 

firehog6305

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Re: Need help 94 Mercruiser 305

you didnt say anything about your outdrive, there is a water impeller in the outdrive that feds water to the engine, its made of rubber, and it should be changed every 2-4yrs
 

Don S

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Re: Need help 94 Mercruiser 305

As firehog mentions. The FIRST thing you check on a boat overheat is the impeller in the raw water pump. A plastic bag that you never see is all it takes to destroy one. Not replacing it after about 3 or 4 years with a gen II drive is also asking for it.
 

Bry21317

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Re: Need help 94 Mercruiser 305

To answer your questions:

The manifold you removed had them blocked, didn't it?
I will be looking at this to find out, I am not sure on this. I have the old manifold, just have to go look at it.

He needs to look at the float/needle/seat to see why it is not stopping the fuel. Remove the regulator. It is a poor bandaid.

I will remove the Bandaid, as this makes no sense to me either. I told him I was not happy about that.

Partially crimped inlet hose, air bubbles from bad "raw water housing/impeller.

We checked the Impeller and had replaced the impeller about 1 month ago. So the impeller was new, just run from a few starts in the driveway, with WATER hooked up every time. I also made him take the lower unit apart at the boat ramp, thinking this was the problem, we looked at the impeller and it looked brand new as it did when he put it in, the Housing is Stainless Steel and looked in good condition to me.

What type of thermo housing do you have? 4 or 6 hose? Did you change this with your intake replacement.

No we did not replace this. I have the 6 hose one. 1 hose on each side goes to the Manifolds, 1 hose goes to the Exhaust risers and then there is the Inlet hose from the Outdrive and the large hose that goes down to the belt driven water pump.

What rpms and mph? Is this the prop you ran before the intake change?
I am getting the same RPMS and Same MPH as I did before, even just with the labbed prop. I get right at 4800 rpms or just over and right at 49.5 gps with the 4 blade REV 4 Prop. Yes this prop I had run before the Change, and it was able to run 48.5 mph gps and 4750 RPMS.

PS: It might be better to keep everything in one thread. Most people won't search to find the prior threads.

I am sorry about this, I will do this from now on then.

Dons,
I Greatly apreciate your answers and all the help that you give in the boards. I do have a manual and I have been boating for 11 years now. This is my first I/O boat that I purchased a year ago. So the I/O is new to me. I am one of those people that does over maintenance on it. I will do my impeller every year no matter what. Even if it looks good I will put a new one in there.

The impeller was replaced about 4 weeks ago. We pulled the lower in the parking lot, as I stated above to check to see if that was the original problem, with no water coming through, like it should. Now if there was a broken impeller in there, I have no clue. I have only had the boat for a year and the impeller I took out was not near broken, and did not look bad at all.

So any other information that you guys can lend would be great.

Thanks,
Bryan
 

Bry21317

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Messages
552
Re: Need help 94 Mercruiser 305

I just checked the old Intake manifold and it has water passages at the front of it, by the thermostat housing area and in the middle of the manifold. It does not have any at the back of the manifold, as they are blocked off.

Thanks for all the help.

Bryan
 

Bry21317

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Re: Need help 94 Mercruiser 305

One other thing. It was getting hot when in Idle or low cruise speed. At Higher RPMS we could use that to cool the engine back down. The temp would drop if we revved the engine up. Even sitting in neutral and rev the engine to 2500-3000 it would then drop the temps.

Just thought of this, it might make a difference, not sure.

Bryan
 

John_S

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Re: Need help 94 Mercruiser 305

"in the middle of the manifold."

No, that is the exhaust crossover passage. Your low profile 2brl cast iron manifiold is like the highrise cast iron one, only has them on th front. Don't let your "mechanic" convice you of another bandaid.
 

firehog6305

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Re: Need help 94 Mercruiser 305

Getting hot at idle or low rpm, then cooling down a liitle at high rpms??? don you would know for sure, better then me, but that sure does sound like a impeller problem
 

Bry21317

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Re: Need help 94 Mercruiser 305

I agree everything tells me impeller also. I am going to stress this.

Is it possible that it has anything to do with the Water Circulating pump, that is belt driven? Because I had gotten the water out of the block and exhaust manifolds and risers, but there hose from the Thermostat cover down to the Water pump, on the engine was frozen once this winter. Could this have anything to do with this? When I found it had ice in this hose, I took a heat gun and melted it, and then left the hose off, so that it would drain.

Bryan
 

Bondo

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Re: Need help 94 Mercruiser 305

Is it possible that it has anything to do with the Water Circulating pump, that is belt driven? Because I had gotten the water out of the block and exhaust manifolds and risers, but there hose from the Thermostat cover down to the Water pump, on the engine was frozen once this winter. Could this have anything to do with this?

Ayuh,...... Anything is Possible......
 

Bry21317

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Messages
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Re: Need help 94 Mercruiser 305

Ok,
After reading through the Merc Service manual this morning. I found there is a spacer that holds the Thermostat down and it is not in there. This also diverts more water out the exhaust without this in place from what I have found out. Here is a picture of the spacer and the spacer itself. http://bpi.ebasicpower.com/mm5/merc...re_Code=eBasicPower&Product_Code=MER23-806922

The part is C in this picture from the Manual.

Thermostat_manual.JPG
 

Bry21317

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Re: Need help 94 Mercruiser 305

Do you guys have any input on my last post on the Missing Spacer?

Bryan
 

John_S

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Re: Need help 94 Mercruiser 305

Are you saying that you never had the spacer or you miss-placed it on the intake conversion?

As far as it possibly causing the overheat, maybe. I am not that familiar with the 6-hose version. Does the thermostat just pop out and lodge in the housing without the spacer?

Did you run on the muffs in the driveway to see if it did overheat? If so, should be easy to retest with the spacer installed.

Not sure on the 6-hose, but the 4-hose has a special grounding gasket between housing and intake manifold. This is the negative ground for the temp sensors in the housing. If you made your own, or aftermarket did not have the ground, you will have problems.
 

Bry21317

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Re: Need help 94 Mercruiser 305

I do not know if the spacer was there. The Mechanic did the Intake conversion for me. And replaced the thermostat when he did this, as I gave him a new one to put in the boat as I had no idea when it was changed last.

There now is no spacer in there and heats up.

All my parts are OEM Mercruiser Parts. There is nothing other than the carb and Intake that are non Mercruiser parts.

Does the thermostat just pop out and lodge in the housing without the spacer?
From what I have found out, this spacer must be there, it acts kind of like the old Popett balls, to keep to much water flow from going out the exhaust without first cooling the engine. Then getting dumped out the exhaust.

Did you run on the muffs in the driveway to see if it did overheat? If so, should be easy to retest with the spacer installed.
I had dropped the boat back off at the mechanics house, so I do not have it at my house to test. I have gotten the spacer from a local dealer hoping this is the fix, he was going to give it a try, as he could not remember if he removed the spacer or if it was in there. I am guessing it was in there and he did not put it back.

Not sure on the 6-hose, but the 4-hose has a special grounding gasket between housing and intake manifold. This is the negative ground for the temp sensors in the housing. If you made your own, or aftermarket did not have the ground, you will have problems.

There is a special type of gasket as you are stating between the Manifold and the Thermostat housing. This is there and working.

Thanks,
Bryan
 

John_S

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Re: Need help 94 Mercruiser 305

Bryan,

It should only take a half hour to install sleeve and retest. It needs to be there and wouldn't let any possible theories get in the way of doing it.

I am only a DIY mechanic that works on my own stuff or help others/friends for no pay. There have been at least three things that you have posted about your "mechanic" that would concern me. The real mechanics that read these threads probably have cringed about much more. I hope after you get your cooling and carb issues ironed out, you look for a more competent marine mechanic.

PS: I assume by "your mechanic" that you are paying for his services. If it is someone just trying to help out (for free or next to nothing), I apoligize to him.
 

Bry21317

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Re: Need help 94 Mercruiser 305

I agree with you. This is the first time I have had anyone work on my boat, and it will not happen again.

I took the part out to him this afternoon, and he installed it. It did not make a difference. I am sure that it needs to be there and it will stay there.

One thing I noticed with him running it in the driveway, was that the water normally comes out of my Thru hull exhaust, this time it was coming out of the prop. So the water is not getting up the hose from the lower unit to the engine. There has to be something in the Lower that is causing it. The water was flowing good through the prop so the impeller was pumping it, it just was not going up the hose to the engine as it should have been.

This is a mechanic that I paid to replace the Prop shaft, Install the new carb/Intake and a new water pump.

I agree, I may not be using his services again once it is figured out. He does seem to be pretty good, but I don't like anyone working on my stuff.

Bryan
 

John_S

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Re: Need help 94 Mercruiser 305

What kind of exhaust do you have? Straight thru hull or like a captains call which have diverters to route to the prop?

Given the mechanics record, would check the water pump tube and o-rings. Also check the supply hose thru the outdrive is not crimped. I'd also check your drive oil for water. The quad ring is common to be forgotten by inexperienced and non-manual followers. It is a small o-ring that needs to be replaced when you seperate the upper and lower to do pump replacement.

I think you would have a genII drive: http://www.boatfix.com/merc/Servmanl/14/14cover.pdf
 
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