Poppet valve kit replacement on Mercury - Moderated Discussion Areas

  ContinuousWave
  Whaler
  Moderated Discussion Areas
  ContinuousWave: Whaler Repairs/Mods
  Poppet valve kit replacement on Mercury

search | FAQ | profile | register | author help

Author Topic:   Poppet valve kit replacement on Mercury

picflight posted 06-24-2014 12:01 PM ET (US)
1998 Mercury 150 EFI 2.5L V6 Off-Shore
I rebuilt the poppet valve on my engine 6 months ago using the widely available rebuild kit, replaced the thermostats and impeller. Engine has been dry docked since then.
Today when I installed the lower unit and ran the engine on the muffs, I noticed a steady stream on water coming from the body of the poppet valve. Seems to be coming out of a weep hole of some kind. This water was filling the lower cowling area of the engine. I tried to take a picture of the stream from the poppet valve but it does not seem to be very clear.
This does not seem normal to me.
Can someone confirm.
Thanks.
https://farm4.staticflickr.com/3919/14477014402_06fb93a691_c.jpg

https://farm6.staticflickr.com/5516/14291878687_c0ffde3073_b.jpg
myakka posted 06-24-2014 09:20 PM ET (US)
It is either perforated again or the pieces slipped during installation. Its been a while. I remember it being tricky to install without something slipping.
picflight posted 06-25-2014 05:56 PM ET (US)
Actually it was not difficult to install, only time consuming part was holding the gasket and face plate together.
It looks like a weep that was putting out the water.
I forgot to lower the pressure of the water hose to see if the hose pressure was doing it.
sosmerc posted 06-26-2014 05:58 PM ET (US)
Either the diaphragm was not positioned quite right, or one of the gaskets. Water is NOT supposed to come out of that hole. The hole is a vent hole to let air in on one side of the diaphragm.
RevengeFamily posted 07-01-2014 07:50 AM ET (US)
sosmerc is dead on...
I've replaced the assembly on my 1999 225hp Optimax's... Easiest way to do the job is to remove the lower cowling... This gives you plenty of space to see what your doing...
Had a diaphragm tear when I was 10 miles off the beach one day... salt water filled the lower cowling and started shorting out the coils for cylinders #5 & 6...
I know it's a new assembley, but check for a torn diaphragm or misaligned gaskets...
Good luck, and let us know what you find...
Norm
picflight posted 07-14-2014 01:20 AM ET (US)
Tried running the engine with low pressure on the hose, just enough to get a good stream from the tell-tale and yet there was water coming out of the weep hole.
The Poppet valve assembly is so basic, I made sure that it was put back together just as I took it off, the gaskets, diaphragm, spring and the poppet valve itself.
What is the issue that is causing water to come out of the weep hole?
Is it a blockage somewhere or the diaphragm is stuck?

I noticed that there is was water coming out from where the Zinc is installed just above the anti-ventilation plate.
Is this normal?

See 50 sec video link below.
http://youtu.be/hBF4ekbTZlI
RevengeFamily posted 07-14-2014 06:54 AM ET (US)
If the diaphragm were stuck, I would suspect that the spring was broken. I have my doubts about that stainless spring being broken.
Water should not be coming from the hole. It's not a weep hole for water. It's a vent hole to allow air to either escape or enter in under the metal retaining cap. As the diaphragm moves in or out the air volume under the cap must change.
Either the diaphragm is torn or was installed incorrectly...
Norm
picflight posted 07-14-2014 12:59 PM ET (US)
It was a new kit, not OEM that I used to rebuild the poppet assembly, spring, diaphragm, washer, gaskets, valve and carrier.
I plan on opening it up today and take pictures to get some some feedback.
I have another OEM Kit that I got last week, 803062T-1, I will install that today and test.
Is there a better, clearer diagram other than the one in the parts catalog that shows the correct orientation of the parts?
picflight posted 07-15-2014 09:34 PM ET (US)
Took the poppet valve off this evening.
This is what it looks like, was it installed correctly?
https://farm4.staticflickr.com/3880/14479077418_8a105da1e8_b.jpg
https://farm4.staticflickr.com/3904/14479026400_2628c6d93a_b.jpg
https://farm4.staticflickr.com/3868/14665351312_efac922173_b.jpg
Does the screw get tighten all the way where it compresses the spring as I am doing in the third picture?
The uncompressed height of the spring of the OEM kit is 1 13/16".
picflight posted 07-15-2014 10:55 PM ET (US)
Should the screw on the Poppet valve be tighten such that the Poppet base is sitting flat on the Deflector plate, item 16 16496; DEFLECTOR, Water on the diagram?
In this scenario the spring is compressed all the way.
sosmerc posted 07-20-2014 11:32 PM ET (US)
the screw should be tightened until it bottoms out on the poppet valve. (otherwise, water can creep around the screw and escape via the air vent hole in the housing)
picflight posted 07-21-2014 12:12 PM ET (US)
Thank you for the response sosmerc.
I got a torque screw driver and followed the service manual, which stated 25lb in torque on that screw.
The torque limiter did not trigger while the poppet valve had bottom out, so I stopped tightening it at this point.
I will test run the engine in couple of days after I figure out another unrelated issue I discovered.

Hop to:

Contact Us | RETURN to ContinuousWave Top Page

Powered by: Ultimate Bulletin Board, Freeware Version 2000
Purchase our Licensed Version- which adds many more features!
© Infopop Corporation (formerly Madrona Park, Inc.), 1998 - 2000.

Author	Topic: Poppet valve kit replacement on Mercury
picflight	posted 06-24-2014 12:01 PM ET (US) 1998 Mercury 150 EFI 2.5L V6 Off-Shore I rebuilt the poppet valve on my engine 6 months ago using the widely available rebuild kit, replaced the thermostats and impeller. Engine has been dry docked since then. Today when I installed the lower unit and ran the engine on the muffs, I noticed a steady stream on water coming from the body of the poppet valve. Seems to be coming out of a weep hole of some kind. This water was filling the lower cowling area of the engine. I tried to take a picture of the stream from the poppet valve but it does not seem to be very clear. This does not seem normal to me. Can someone confirm. Thanks. https://farm4.staticflickr.com/3919/14477014402_06fb93a691_c.jpg https://farm6.staticflickr.com/5516/14291878687_c0ffde3073_b.jpg
myakka	posted 06-24-2014 09:20 PM ET (US) It is either perforated again or the pieces slipped during installation. Its been a while. I remember it being tricky to install without something slipping.
picflight	posted 06-25-2014 05:56 PM ET (US) Actually it was not difficult to install, only time consuming part was holding the gasket and face plate together. It looks like a weep that was putting out the water. I forgot to lower the pressure of the water hose to see if the hose pressure was doing it.
sosmerc	posted 06-26-2014 05:58 PM ET (US) Either the diaphragm was not positioned quite right, or one of the gaskets. Water is NOT supposed to come out of that hole. The hole is a vent hole to let air in on one side of the diaphragm.
RevengeFamily	posted 07-01-2014 07:50 AM ET (US) sosmerc is dead on... I've replaced the assembly on my 1999 225hp Optimax's... Easiest way to do the job is to remove the lower cowling... This gives you plenty of space to see what your doing... Had a diaphragm tear when I was 10 miles off the beach one day... salt water filled the lower cowling and started shorting out the coils for cylinders #5 & 6... I know it's a new assembley, but check for a torn diaphragm or misaligned gaskets... Good luck, and let us know what you find... Norm
picflight	posted 07-14-2014 01:20 AM ET (US) Tried running the engine with low pressure on the hose, just enough to get a good stream from the tell-tale and yet there was water coming out of the weep hole. The Poppet valve assembly is so basic, I made sure that it was put back together just as I took it off, the gaskets, diaphragm, spring and the poppet valve itself. What is the issue that is causing water to come out of the weep hole? Is it a blockage somewhere or the diaphragm is stuck? I noticed that there is was water coming out from where the Zinc is installed just above the anti-ventilation plate. Is this normal? See 50 sec video link below. http://youtu.be/hBF4ekbTZlI
RevengeFamily	posted 07-14-2014 06:54 AM ET (US) If the diaphragm were stuck, I would suspect that the spring was broken. I have my doubts about that stainless spring being broken. Water should not be coming from the hole. It's not a weep hole for water. It's a vent hole to allow air to either escape or enter in under the metal retaining cap. As the diaphragm moves in or out the air volume under the cap must change. Either the diaphragm is torn or was installed incorrectly... Norm
picflight	posted 07-14-2014 12:59 PM ET (US) It was a new kit, not OEM that I used to rebuild the poppet assembly, spring, diaphragm, washer, gaskets, valve and carrier. I plan on opening it up today and take pictures to get some some feedback. I have another OEM Kit that I got last week, 803062T-1, I will install that today and test. Is there a better, clearer diagram other than the one in the parts catalog that shows the correct orientation of the parts?
picflight	posted 07-15-2014 09:34 PM ET (US) Took the poppet valve off this evening. This is what it looks like, was it installed correctly? https://farm4.staticflickr.com/3880/14479077418_8a105da1e8_b.jpg https://farm4.staticflickr.com/3904/14479026400_2628c6d93a_b.jpg https://farm4.staticflickr.com/3868/14665351312_efac922173_b.jpg Does the screw get tighten all the way where it compresses the spring as I am doing in the third picture? The uncompressed height of the spring of the OEM kit is 1 13/16".
picflight	posted 07-15-2014 10:55 PM ET (US) Should the screw on the Poppet valve be tighten such that the Poppet base is sitting flat on the Deflector plate, item 16 16496; DEFLECTOR, Water on the diagram? In this scenario the spring is compressed all the way.
sosmerc	posted 07-20-2014 11:32 PM ET (US) the screw should be tightened until it bottoms out on the poppet valve. (otherwise, water can creep around the screw and escape via the air vent hole in the housing)
picflight	posted 07-21-2014 12:12 PM ET (US) Thank you for the response sosmerc. I got a torque screw driver and followed the service manual, which stated 25lb in torque on that screw. The torque limiter did not trigger while the poppet valve had bottom out, so I stopped tightening it at this point. I will test run the engine in couple of days after I figure out another unrelated issue I discovered.