New 5.7L Mercruiser Long block - Wont Start/Run

Ryanmash

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Jun 11, 2018
Messages
5
Hi all,
Long time lurker, first time poster. I must admit I find a great deal of information and answer within this forum however I have become absolutely stumped. Wanted to reach out to this community to see if I can generate an answer.

About the boat - 1995 26ft Thompson 5.7l Mercruiser EFI, Alpha one gen II. Long story short had a blown head gasket at the end of the season water leaked on top the piston rusted the cylinder walls bent connecting rod. Now that we cleared that up, went out bought a new Mercury long block pre-vortec roller cam, removed necessary components from the old engine to the new. Replaced old distributor rotor and cap, have it pointed to no.1 cylinder TDC. Dropped engine into the boat and it turns over great get just enough fuel to burn and then shuts down. I can pour gas into the throttle body to get the engine to run, I can also see the injectors "misting" fuel. I can continue to add gas to keep the engine running however when I stop the engine will die.

My initial thought was the fuel pump was not delivering enough fuel so took the line off the throttle body and started the engine with gas and pumped the fuel into a bottle. This tells me the fuel pump is working properly as it filled the bottle in a matter of seconds. Next step I thought the injectors were dirty, so I pulled them off bought the rebuild kit and put it back together, no dice same problem. Got to reading on here and saw a post about a TPS and IAC sensor. So again I started the motor with gas, and disconnected the TPS sensor and the engine would go up to 3000 rpms but it would continue to run. So I figured ok TPS sensor is shot, went to parts store bought a new sensor, installed it, and same results.

At this point I have a day used up trying to find a solution. Found a link on this forum on how to create own test kit to determine engine error codes. Followed the instructions and pulled code 21. TPS voltage high. I am not exactly sure what that means or how to solve.

This is really strange as the old engine worked great never had any issue and now swapped it over to a new long block and i cannot get this thing to run at all. Hoping someone here can give some insight.

Thanks in advance,
Ryan
 

garbageguy

Lieutenant Commander
Joined
May 8, 2012
Messages
1,598
Not an engine expert. Have you checked at anti-siphon valve? That kept us from running after a 5.7 repower a couple years ago
 

Ryanmash

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Joined
Jun 11, 2018
Messages
5
I kind of breezed past anti-siphon as i'm getting fuel out of the pump into the TBI system so figured thats not the issue. I could be wrong, what needs to be done on the anit-siphon valve?
 

alldodge

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Mar 8, 2009
Messages
42,587
pulled code 21. TPS voltage high

The hot lead is shorted to a 12V source, it should only have 5V on it

Measure the pins with a volt meter to see if one has more then 5V,

Also see if you have 12V on the Red leads on the injectors.

Next measure fuel pressure at the TB, should be 30 psi

91_806901.jpg
 

Ryanmash

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Joined
Jun 11, 2018
Messages
5
Thanks AllDodge, i'll look into this, it does act sort of like a short so I feel this is a very plausible cause.
 

Ryanmash

Recruit
Joined
Jun 11, 2018
Messages
5
Just to update - I found the issue! When replacing the engine the fuel lines coming off the water separator were in the wrong places. I swapped them around and it runs like a top. I am still confused as to what is different between the two lines? If they truly are different, I can't believe this hasn't been fool proofed. Oh well I hope my time lost is someone else time gained!
 

garbageguy

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May 8, 2012
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1,598
Glad you found your problem and are off and running - and thanks for sharing your story
 

alldodge

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Staff member
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Mar 8, 2009
Messages
42,587
Just to update - I found the issue! When replacing the engine the fuel lines coming off the water separator were in the wrong places. I swapped them around and it runs like a top. I am still confused as to what is different between the two lines? If they truly are different, I can't believe this hasn't been fool proofed. Oh well I hope my time lost is someone else time gained!

I'm a bit amazed my self, it would run much at all. One is high pressure and one is the return. So the high pressure was going into the back side of the regulator and bypassing any regulation. Your boat probably had close to 60 psi pressure. If you start seeing other things like it still being a tad rich, then check pressure at the rail. This may have damaged the regulator
 
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