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1989 Merc 9.9 water entering lower cylinder #4434499
06/17/17 06:14 PM
06/17/17 06:14 PM
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
Bluestream Offline OP
Bluestream  Offline OP
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
I have a 89 Merc 9.9 That runs rough at idle and higher speeds. Lower plug always looks wet/grey emulsion and often small water droplets on.

Compression good at 105 PSI in both, gas is fresh and 50:1
New plugs installed, both getting good spark. (has aftermarket CDI box)
Carb (has carb from an 8HP) was taken apart and was spotless. Fuel needle/seat held pressure for 10 min, float set to 1 inch
Reeds appeared to be good and sealed tight
Float was good and main jet clean
Low speed jet at 11/4 turns out

I have replaced the exhaust cover gaskets and they looked fine, but still same issue. (I could see water in lower with cover off)
Is there any way for water from cooling system to enter the cylinder? I have heard lower seal can let water in, any truth to that?


2000 VW Beetle 1.8T M5
2000 Ford Explorer 4.0 4X4
1991 BMW 735iL
"A fool and his money are soon parted" - Thomas Tusser
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4434581
06/17/17 07:50 PM
06/17/17 07:50 PM
Joined: Mar 2004
Posts: 20,758
Upstate NY
Donald Offline
Donald  Offline
Joined: Mar 2004
Posts: 20,758
Upstate NY
It's been awhile since I have fooled with an outboard. What about the head and head gasket?


2015 Subaru Forester 2.5 engine/CVT
2015 Ford F250 w/Powerstroke
2016 Subaru Crosstrek CVT (wife's)
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4434686
06/17/17 10:20 PM
06/17/17 10:20 PM
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
Bluestream Offline OP
Bluestream  Offline OP
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
These merc's have no head. Cylinder/head is all one piece, but if they had a head, the gasket would be the first place to look


2000 VW Beetle 1.8T M5
2000 Ford Explorer 4.0 4X4
1991 BMW 735iL
"A fool and his money are soon parted" - Thomas Tusser
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4435088
06/18/17 12:11 PM
06/18/17 12:11 PM
Joined: Aug 2003
Posts: 10,782
Buffalo, NY
JTK Offline
JTK  Offline
Joined: Aug 2003
Posts: 10,782
Buffalo, NY
Seems like a leak in the cylinder jug between the water jacket and cylinder somewhere, but like you say, the compression tests OK. It would have to be a minuscule leak that only crops up under certain conditions. Ugh..


2017 Ram 1500 4x4, 3.6L. 2016 Nissan Quest SV (Babe magnet IV)
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4435137
06/18/17 01:00 PM
06/18/17 01:00 PM
Joined: May 2006
Posts: 4,013
Central Wisconsin
dwendt44 Offline
dwendt44  Offline
Joined: May 2006
Posts: 4,013
Central Wisconsin
The exhaust covers could be a place that might have a leak.
The cover over the exhaust could be rotted or cracked, the water jacket
cover over that cover would supply the water.

Though I'm more familiar with larger O.B. engines.

My 2


There's no such thing as:
Too big of a battery,
Too large of a gas tank,
or too loud of a horn,
or too bright headlights.
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4435162
06/18/17 01:29 PM
06/18/17 01:29 PM
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
Bluestream Offline OP
Bluestream  Offline OP
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
I have replaced the exhaust cover gaskets as mentioned in 1st post. The covers and the inside were pristine as a fresh water engine.

First image shows the gray water oil mix by lower exhaust ports




Last edited by Bluestream; 06/18/17 01:33 PM.

2000 VW Beetle 1.8T M5
2000 Ford Explorer 4.0 4X4
1991 BMW 735iL
"A fool and his money are soon parted" - Thomas Tusser
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4435583
06/19/17 12:01 AM
06/19/17 12:01 AM
Joined: May 2006
Posts: 4,013
Central Wisconsin
dwendt44 Offline
dwendt44  Offline
Joined: May 2006
Posts: 4,013
Central Wisconsin
Use a straight edge to make sure that both plates are flat.
If the tattle-tale and the exhaust path are clear, there should be no
back pressure on the cooling flow.


There's no such thing as:
Too big of a battery,
Too large of a gas tank,
or too loud of a horn,
or too bright headlights.
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4435699
06/19/17 08:31 AM
06/19/17 08:31 AM
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
Bluestream Offline OP
Bluestream  Offline OP
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
Thats good advice, I will check them for trueness. I assumed that because they were so thin the clamping force of the bolts would pull the cover in tight even if they were a bit off.

Other sites have suggested the lower crank seal may be bad, but I cant see how that would matter, as that area is not exposed to any water.


2000 VW Beetle 1.8T M5
2000 Ford Explorer 4.0 4X4
1991 BMW 735iL
"A fool and his money are soon parted" - Thomas Tusser
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4435878
06/19/17 11:59 AM
06/19/17 11:59 AM
Joined: May 2006
Posts: 4,013
Central Wisconsin
dwendt44 Offline
dwendt44  Offline
Joined: May 2006
Posts: 4,013
Central Wisconsin
Quote:
Other sites have suggested the lower crank seal may be bad, but I cant see how that would matter, as that area is not exposed to any water.


True. The water has to come from the block itself, it's not under much pressure
and it should flow right back out normally. If the propeller is open and the lower
unit hasn't been worked on prior to the problem, I'd check the water outlets all the
way down to the prop.

My 2


There's no such thing as:
Too big of a battery,
Too large of a gas tank,
or too loud of a horn,
or too bright headlights.
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4436148
06/19/17 06:49 PM
06/19/17 06:49 PM
Joined: Mar 2004
Posts: 20,758
Upstate NY
Donald Offline
Donald  Offline
Joined: Mar 2004
Posts: 20,758
Upstate NY
Maybe better done in January, but stop in to a Merc dealer and pick his brain. He should give you some advice if you hint you will buy the needed parts from him.


2015 Subaru Forester 2.5 engine/CVT
2015 Ford F250 w/Powerstroke
2016 Subaru Crosstrek CVT (wife's)
Re: 1989 Merc 9.9 water entering lower cylinder [Re: Bluestream] #4438912
06/22/17 08:06 PM
06/22/17 08:06 PM
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
Bluestream Offline OP
Bluestream  Offline OP
Joined: Sep 2003
Posts: 5,770
Waterloo, ON
Yeah, I've been to the dealer a few times. Parts guy only offers so much info, or only knows so much. Said 99% of the time its exhaust cover gaskets. I have re-seal the gaskets with loctite 518. I will pressure test the cooling system to see if the block is cracked. Not sure what else to do....


2000 VW Beetle 1.8T M5
2000 Ford Explorer 4.0 4X4
1991 BMW 735iL
"A fool and his money are soon parted" - Thomas Tusser

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