Mercury 150 xl 2 stroke, carbureted, head temperatures vary by 15 to 25 degrees

jetksi21

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2002 Mercury overheating to about 160 to 175 degrees. Poppet valve stuck partially open, replaced. Pump, thermostats, grommets were replaced when the motor mounts were replaced last fall. Checked the head temperature using infrared gun. Thermostats started opening at about 130 degrees(small trickle) and at around 140 degrees plus I was getting full flow. Water pressure at idle right under two pounds( and yes this is the correct pressure for this engine). Temperature checked at all spark plugs in two places - about a 1 1/2"(flat spot on head) horizontal to the plug both left and right side of plug. Why? On a previous test I noticed the middle cylinder right bank was running about 15 to 20 degrees hotter than all the rest of cylinders but was only this hot to the right side of plug. The left side was hitting about 139 degrees. All cylinder head temperatures were higher on the outside both left and right heads. The top cylinder left bank reading about 148 degrees both sides of plug and only cylinder that did not have an increase in temperature to the right of plug? Don't have any idea how the water flows and all I can figure out is the flow is directional and something is blocking that flow on both exterior sides of head. Also in the Mercury cooling flow diagram how can you have a line on the pressure side and it be called a discharge line???
 

Dukedog

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Oct 6, 2009
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really..

gettin' an over temp warning buzzer?.. its an "open" coolin' system... are you takin' all these readings under a load at different rpms in tha lake or ona hose in tha driveway?

been around a lotta V6 mercs ('76 ta '08, production and high perf.) and have never seen merc say tha 2 lbs at idle is ok except some early Hi Perf. 260's???
 
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jetksi21

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really..

gettin' an over temp warning buzzer?.. its an "open" coolin' system... are you takin' all these readings under a load at different rpms in tha lake or ona hose in tha driveway?

been around a lotta V6 mercs ('76 ta '08, production and high perf.) and have never seen merc say tha 2 lbs at idle is ok except some early Hi Perf. 260's???
 

jetksi21

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Temperature not high enough to set off alarm(205-210). As far as pump pressure, it came from Mercury.
 

Dukedog

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don't care where it came from.. 2 lbs is not good............. unless its onna hose.
 

Dukedog

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do whatever ya want but ona hose ya not gonna get true and consistent information with either temp and/or pressure at any rpm...... jmo.
 

jetksi21

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Never had a problem with any readings at idle. First of all, any time you are running on a hose the engine should never be above idle, inboard or outboard. Any tests above idle the engine should be submerged. You can't tune an engine on a hose. Also, inboards will collapse the hose above idle because of the larger volume they put out.
 

Dukedog

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sounds like ya got it all figured out then............ first of all i don't need instructions on anything 2.0, 2.4, 2.5 V6 Merc.. good luck with it.
 

Makomadness

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Jun 5, 2022
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Was the overheat test and measurement done on the hard or in the water?
If on the hard were muffs used?
Did you see a decent pee stream?
Does the motor overheat at idle or only when run at higher revs and/or speeds?
If it runs hot at idle do the temps come back to normal when the revs are raised?

I believe the 2 psi water pressure you mentioned is from the engine pressure monitor. 2 psi at low revs is fine but it should increase as revs are increased. If the poppet doesn't open, the pressure will go high. I have optis so I can't be sure of the exact numbers but when the poppet finally opens, the pressure at cruise revs is about 7 psi or so. It may go over that number before the poppet opens but will drop when the valve does open.

As mentioned, the overheat logic trips at a higher temp than 170 degrees but I have seen on multiple occasions where I get an overheat alarm even though temps at the temp sensors are normal. Note that it is the temp switch(not sensor) that triggers an alarm as far as my motors go.
 

jetksi21

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Sep 20, 2009
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Thanks for the reply. Well, I believe I found the problem - lime/scale buildup in heads. Will post final results when through.
 
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