496 Mercruiser Runs Rough Until Warm

Joined
Apr 18, 2022
Messages
2
Good Evening iboaters.

Long time (many years) of reading, first time posting (my good luck with boats is hopefully only temporarily being challenged).

I have read many forums with similar issues and tried a few things that did not correct the issue.

Here is a quick over-view. I have a 2007 Mercruiser 496 (non H.O.) motor. I bought this boat used with only 93 hours 3 years ago, was expecting some mild issues due to lack of use. Instead a blew the block 3 hours in a 96 hours without even running it hard. 12 grand later I have a new block with existing components put back on it.

My issue is this, boat turns over and starts, but dies right away. Then another turn of the key or two with the motor cranking for about 2-3 seconds it catches and starts, it chugs along at a low rpm for a couple seconds and dies. If I start it a third time it will chug along at a low rpm but manage to stay alive and slowly the rpms come up to a normal warming the engine speed. Once it gain RPM but the engine is still not warm if I were to rev the engine it would cause it to bog down and die, I can advance the throttle and if i pull back quick enough it will stay alive. While advancing the throttle and its bogging down the engine you can hear a steady air sucking sound. This (along with some forum posts) led me to believe it was the IAC valve so I changed it, there was no difference. In the throttle body there are IAC filters I believe they are called, I replaced those, no difference. I brought it into my nearest marine mechanic (unfortunately not mercruiser mechanic) he ran his diagnostic tool on it and this is what they found.

"Upon initial Fire up crank position sensor and cam position sensor codes showed up. However after a few minutes of idling and engine was warm codes went away"

The boat runs perfectly once warm, sadly I ran it this way with the hard starts for two seasons, but tried not to use the boat too much due to this, as i don't believe its good for the motor to barely stay alive and chug along each warm up. This year I have to get this fixed. Nearest mercruiser mechanic is over an hour away by trailering it, if I cant figure it out I guess I will have to drag it in there and likely leave it there a month as they are swamped with boats.

I have always run 91 octane fuel in this motor since I have owned it, its up at about 120 hours now, a little under 30 on the new block.

I have videos of the motor struggling to warm up, but they are to large to post.

Thank you for any help/ideas you may be able to give me, much appreciated.
 

Fun Times

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May 16, 2009
Messages
9,078
Hi there, just a few things to mention.

By design the 496's run better on 87 vs 91 octane and have a small effect on running as it might be fouling the spark plugs IE: slightly richer running/build up on the outer transom area...Have you inspected the spark plugs for a rich condition?

Clean the inner throttle body, TB Plate and IAC filter hole area, flame arrestor too.

Make sure the IAC electrical plug connector isn't getting super hot to the touch....Also maybe plug in the old IAC and try to see if it's moving so you know the PCM is trying to allow the IAC to work.

Try oping the throttle about 1/4 way before starting to see if the engine fires off/runs more normal right away.

Next time as a test, before starting the engine, try turning the key on and off at least 2 - 3 times before cranking the engine over to start...in essence build fuel pressure so your all in before the engine starts.

Check fuel pressure.

Remove/inspect the vacuum hose from the fuel regulator to see if fuel is spitting out the regulator vent fitting. It should not be.

Both fuel filters have been changed and fuel module inspected for water, debris, paint chipping.
 
Joined
Apr 18, 2022
Messages
2
Thank you for your Reply.

I had a feeling it would run fine on 87 instead of 91, but i fill my boat by jerry cans at my dock and use 91 so it has zero ethanol.

I have not inspected the spark plugs, I will now though. I have noticed some soot around the outdrive on the transom, but I have noticed this on all my other I/O's, nothing more than those ones, think that's just from when it warms up. I would think a fouled plug would continue to act poorly even once warm, once warm boat runs as new.

I did clean the flame arrestor but did not clean Throttle body plate nor the holes where the IAC filters go, but didn't look bad to the eye, but I will clean them.

I will inspect the IAC electrical connectors after it has been running for some time to see if it is getting hot. I kept the old IAC valve so could plug it in and hold it my hand and check to see the valve actually moves. I guess i should see this if I hold it in my hand while somebody starts the boat for me. I guess this will do no harm the motor running it without an active IAC as the one attached to the motor will be unplugged.

I do believe I tried starting it with applied throttle before cranking and did not help, but my memory is fuzzy on that one so I will try it again.

I do that all the time turn the key 2 or 3 times before starting just to make sure the fuel system is fully primed, problem remains.

I do not have any tools to check fuel pressure with, if it comes down to that than I will have to trailer the boat to the mechanic.

I will check the vacuum hose, I think the problem is some sort of vacuum leak, only because of the noise it makes (sucking air sound) when i rev the engine when it is cold, seems to me like when i do that the motor gets more gas but not more air added, and at that point the motor wants to die.

I will replace fuel filters and water separator, but once engine is worm I can launch the throttle and the boat accelerates smoothly while sucking back gas as only a 496 can lol.

Thank you so much for the taking the time to help me troubleshoot this matter. I'm going to feel rather accomplished if I can get this one myself. I'm an electrician, I have done some repairs on boats over the years, like starters, alternators, and general maintenance, but not so much technical stuff as previous boats were very good to me. Even though this motor has given me problem$ I absolutely love it, so powerful and smooth. I hope after this it will be many good years.
 

alldodge

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Mar 8, 2009
Messages
42,306
Can get a fuel pressure gauge for under $50 and attach to the fuel rail. Don't know where your located but may be able to borrow one from a auto parts store
 
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