Rough idle, some hesitation - both engines

scrumper

Active Member
SILVER Sponsor
Jul 10, 2020
161
Boat Info
1981 310 Vanguard Express
Engines
Twin Mercruiser 6.2 MPI Horizon FWC inboards
This season is turning into one of those one step forward, two back deals.

Recently I changed out the IAC muffler on both my engines which immediately and comfortably solved a low idle and stalling under load at idle issue I was having. That was 3-4 running hours and about 3 weeks ago (we're weekend boaters mostly).

Now both my engines, with new IAC mufflers and clean flame arrestors, are idling roughly. They run fine and smooth at 1,000rpm+, but idle is poor. It's jerky and irregular sounding, almost like a misfire, and is quite low on cold start. Starting is also more difficult than it used to be - in fact yesterday the port engine would only crank half a turn initially, really struggling, until I switched batteries over (and then it cranked ok when I switched them back after it started). The idle can be made to improve by running the engines at 2000-3000rpm in neutral for a few seconds and then bringing it back down to idle, then it's smooth and normal, until a restart.

I can hear the IAC sucking hard if I remove the muffler (which increases idle speed a bit as you'd expect).

I've changed fuel filters (inline and water sep); gas looked pristine with not a drop of water in the filter. (I find this slightly suspicious but there we are - if it's not in the filter, it's not in my engine.)

I'm noticing also some slight hesitation when advancing the throttle on both engines. Say from 1000 rpm, I push the lever forward a bit, then revs drop to maybe 900 for a half second then go up to where you'd expect from the throttle position.

So my plan is:

- Remove and clean each of the IACs in case they're only opening part way.
- Inspect the distributor caps and rotors for wear and corrosion
- Check fuel pressure
- Put my fingers against each of the injectors and see if I can feel them pulsing
- Check the engine grounds with a multimeter and inspect all the ground cables to the battery banks for corrosion.

What else should I add to my list of things to check?

It's super weird that both engines are developing a similar fault. I'm almost tempted to blame the fuel I recently added, but it looks and smells fine and it's a very, very busy gas dock. The hot weather too, maybe a factor?

I'm not going to start plopping parts in with no justification. I'm on the fence about investing in an Rinda, too. I think that might get me some answers quickly.

Frustration grows here.

Thanks for any advice!
 
Definitely sounds like the IAC's. Changing the IAC mufflers may have highlighted that they were on the way out. Id try changing one IAC to start and see what happens. You will know for sure. If it does not fix it then carry on troubleshooting and you will still have a spare IAC for later on.
 
Yeah thanks radscoot, it's #1 on the list. Forgot to say that I did notice that they were both quite hot to touch after only a couple of minutes of running. That seemed weird for something that's just passing air. Are they normally hot?
 
Yeah thanks radscoot, it's #1 on the list. Forgot to say that I did notice that they were both quite hot to touch after only a couple of minutes of running. That seemed weird for something that's just passing air. Are they normally hot?
No i don't think they should be Hot. I believe that is an indication that they are sticking when the ECM activates them and they are being worked too hard.
 
Excellent. That's a good start. Thanks. May not be all my problems but seems like it's one of them.
 
Well the new IAC fixed my port engine. Starboard is still showing the same issue - hard to start (needs throttle), very rough idle around 490-510, but runs great at like 700rpm and up. During investigations I noticed that the throttle cable is sticking so that's a necessary change - I did the port one at the start of the season. But that can't be my problem.

The distributor contacts are slightly pitted in the cap. Photo attached: is that really bad? Doesn't seem awful?

Next up is to check the engine grounds and go over the ground cables all the way back to the battery.

IMG_3318 (1).jpeg
 

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