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1984 Merc 488 3.7l stuck valve and water/oil mix

coachant

New member
Hi all,
1st thanks for all the suggestions with the carb, ended up with an Edelbrock 1409. Simple install, only had to drill out a hole in the existing plastic end of the throttle linkage and create a small custom fuel line from the fuel pump to the carb.

So today everything was buttoned up, checked the oil, put in new plugs, primed the fuel system and fired it up, well tried to fire it up. The timing was off a bit and after about 15 min of getting everything dialed it I could tell something was hurt. Pulled the plugs and did a quick finger compression test, the result, #2 was dead. Pulled the valve cover and it was a mess. The #2 exhaust valve was stuck open, the push rod was bent, and I could tell water got in the system. Each of the rockers had rust on them, mainly in the middle, and there was a light oil/water mixture everywhere. I rechecked the oil and it went from new and clean to mixed with water.

A little background, in the winter the boat had a cover over it but ended up having a leak right over the engine. The engine cover was not over the engine so water was pouring over the engine all winter. The flame arrestor was also off the carb (missing when I bought the boat). I pulled the head and it looked like #2 was full of water with the piston almost to the top. I assume it was in the exhaust stroke when it filled with water and seized the valve. The valve it not bent but stuck in place. The head gasket looked good, no breaks or indication anything went wrong.

I'm the 1st to admit I don't know much about marine inboard engines. There are water lines everywhere!!! Is the engine gone? It turns super easy, all cylinders move up and down freely with little effort when turning the crank manually. I need to take the head in but before going down that road I wanted to ask the experts here. The oil was clean but after hooking up the water muffs and turning the motor over for 15 min there was an oil and water mix. Not sure where it came from, it does not look like anything came from the closed system side, no drop in the water level so I suspect something was in the engine somewhere from the rain/holes in the cover or something came in from the fresh water side. The engine got a lot of water poured over it, we had a very wet fall/winter/spring.

What would you do? Worried about how the oil/water got mixed in. No cylinder cracks I can see, head gasket looked fine, lots of rust inside the exhaust manifold and the exhaust elbow, some pitting at the top of #2 but that was likely due to water from the rains (not sure how it got in on the exhaust side). What else should I check?

Another question, the exhaust elbow gasket to the exhaust manifold was solid and blocked off all water passages, I see the replacement online has one of the four passages open.

Thanks in advance of any and all help. I will post some pics in a little while, need to resize them.

Thanks!!!
 
Stuck valve https://pix.sfly.com/9Cov8m
Cylinder #2 stuck exhaust valve and rust https://pix.sfly.com/avR98-
Cylinder #2 exhaust valve stuck, rust https://pix.sfly.com/e569EF
Cylinder #2 exhaust port, rust https://pix.sfly.com/kZf3_x
Oil/Water in block https://pix.sfly.com/5rw6U6
Oil/Water drained from pan https://pix.sfly.com/ydGVEW
Exhaust elbow to bellows https://pix.sfly.com/XJ2Rxm
Elbow gasket with no water passage cutout https://pix.sfly.com/FcOJHv
Exhaust elbow passages https://pix.sfly.com/1tGWng
 
With that engine I would say you are in over your head.
No pun.

Your lack of understanding of "marine" ....
The history of that specific engine (very long and very bad)

You would be far better off starting over with a newer boat with a v6 or v8 which parts and problems are far easier to address.

If you search any marine forum on this engine you will learn fast.

If you plan on keeping it and making it work, expect a few thousand dollars in rework/repair. That also means boat is down for weeks/months.

GET A MERCRUISER MANUAL!!
 
coachant, as you will learn from reading here and from further searching, the Merc 170, 190, 470, 485 and 488 3.7L engine has been problematic from day #1.
This was Merc's bastard child and was built using Merc's own designed "steel sleeved" aluminum cylinder block using the 385 series Ford 460 cast iron cylinder head.

common issues:

....... OEM stator style charging system will develop issues, if not already.
....... the front end of the chain/sprocket driven camshaft drives the coolant circulating pump impeller, of which means that there is a shared seal in this area that will eventually fail.
....... front cover is prone to warping.
....... they are more prone to damage regarding slight over-heating.
....... the early models used a heat exchanger that was under-sized.
....... they do not fair well in the higher RPM range.


I suppose that you could repair the cylinder head, roll the dice, and give it try!




.
 
Last edited:
Thanks everyone! I have been reading up on all the issues with this engine, was wondering if it was worth investing another few hundred on the head or bail on it. What will bolt up to this? I'll look around on this forum to see if someone else has successfully done a swap.

While pulling everyone off I really liked the simplicity of this design, from a basic building block standpoint. But all these water passages and history of failed parts which will eventually plague this engine even if the head, lifters, push rods resolve my current issues. Probably time to bail while I am only down $1K (boat price included).

Thanks!
 
When looking at other boats, what Merc engines are good? I have been following a few boats online for the past couple weeks, both have 3.0l Merc engines. One is a 1996 175 SeaRay and the other is a 2004 175 Bayliner. What year/engines did Merc start turning things around for the better?
 
Its not a question of when.
Merc introduced your engine for a few years and had nothing but problems and then discontinued it.

All other engines have a positive proven record
 
Stay away from all 4 cylinder boat engines. Stay away from earlier 4.3 v6's (pre 1994) Spend the extra money and purchase a newer than 1990's boat, You will be happier in the long run.
 
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