1996 Four Winns Horizon 200

[kodyman84]

Sounds good. I was concerned about where the pieces of the old impeller ended up. I found quite a bit inside the housing of the impeller itself. But I will be pulling open the t-stat for sure checking that all out and replace the stat.

For the exhaust test without running the engine it’s basically the same as I did earlier tonight...except don’t disconnect the hose coming from oil cooler to tstat housing ( and place in bucket like I did)?

Ive has pretty good luck so far with Crowley marine for part numbers and searching amazon or google for them.

 

[kodyman84]

I ordered the gasket for the water clean out on the drive but it won’t be here until Thursday...which is going to be close for me. Supposed to take the boat camping this weekend with the family and an really trying to get everything done in time.

in a pinch do you think just putting some rtv gasket maker on it would work?

 

[Lou C]

another source for parts which is linked to iboats:
www.volvopentastore.com
even though you have an OMC branded engine the parts are the same, the trick is figuring out Volvo's arcane model # system to see what crosses to yours...
the exhaust test I described will mimic what happens with the engine running, when its cold and the stat is closed, all the water from the impeller goes out the exhaust
then when the engine warms up and the stat opens, the hot water in the engine exits through the manifolds and cold water coming in mixes in getting sucked into the engine
this is why closed cooling is so much better, the engine has a consistent internal temp and the antifreeze under pressure, can remove much more heat than plain old raw water
Not sure if RTV gasket maker will work but it might if you really let it set up before installing. Then to test it you can run it on the water hose with that cover off to check for leaks.

 

[kodyman84]

Thanks Lou! I actually ordered the gasket through iboats

I also order some of the aviation sealant you recommended and an IR temp gun from amazon. Figured it wouldn’t hurt to have one laying around, and for 20 bucks you can’t go wrong.

 

[kodyman84]

I’ll keep you guys all posted of my progress. Going to run that other water test tonight for the exhaust. Hopefully get the shift control cable in and new impeller and possibly even open up the tstat housing!!

 

[kodyman84]

Phew what a day! Work kicked my rear end, and so did this boat. Someone should have told me that you can’t be 6 foot tall with broad shoulders and ape hands to work on these things! Haha! Anyways...

good progress tonight!

Ran the water test from the impeller housing hose that runs to steering oil cooler and then the rest of system. Water came out of the transom exhaust as it should...so no exhaust blockages, at least not major ones.

Pulled off the entire impeller housing so I could get a good look inside, good thing I did there was a small piece of old impeller still inside and looks like it could use a little clean up.

pulled the hoses off the tstat housing and got it removed, prepared the mating surfaces for new gasket. Boy howdy was that stat in bad shape all rusted up...when I put a pair of pliers on it the damn thing basically fell apart! Almost certain it wasn’t functioning as it should be!!

Got the new shift control cable installed, works like a charm. Majorly stoked about that, kind of a pita to get it ran through the hose and transom. But nevertheless pleased with the function!

Feeling pretty good about this weekends camping trip and launch!

 

[Lou C]

Good luck with it. I/Os are easy to work on if you are built like a jockey or a 12 year old kid lol. I had the rear seats out of mine the whole time I did the upper end rebuild last summer (2 re-man cyl heads and all new gaskets, new exhaust and converted to a Holley 4160 4bbl). Next boat will be an outboard, 100%. Getting too old for this.

 

[kodyman84]

Welllll....got her in the water this morning. I’ve now got forward and reverse gears like I figured I would. But immediately starts to overheat.

hit the exhaust elbows with the IR gun and both read 215. Outlet hoses from the tstat housing hoses to exhaust manifolds read 160. Tstat housing itself read about 208.

I have a new new tstat and impeller just installed. Going to open up the impeller housing and see if anything is left.

Not sure where to go next with this effin thing.

 

[Lou C]

Yep your manifolds should be about 85-100 at idle, the 160 coming out of the stat housing sounds high, mine is usually a little over 100, and the t stat housing, more like 135/140. It sound like either you are not getting enough raw water flow (this can be tested by putting the boat in the water and disconnecting the impeller to t stat housing hose at the t stat). Start the engine briefly and see what kind of flow you get out of that hose from the impeller. In my OMC manual it say a 2"-4" head of water should been seen but Volvo may have a different spec. The hot exhaust in particular suggests low raw water flow or clogged elbows but you checked for that, right? The few gotchas on the SX are the water tube gaskets inside the outdrive that can rot out and leak water and the plastic nipple that is in the pivot housing and this can crack & leak if the plug in the pivot is not removed to drain water from it when winterizing. You sure you got the t stat in right? (the rubber ring holds it up in the housing, it does not fit in the hole in the intake manifold like a Chevrolet auto application)….might want to pull it out and test it to make sure it is opening at 160* F as it should....

The OMC Cobra is very similar so I am familiar with these points. How good was the flow out of the exhaust? Look like this?​

https://www.dropbox.com/s/ysj65t93un..._2520.MOV?dl=0

like I said before you gotta verify your IN and OUT water flow....most of my overheating issues over the years have been due to a lack of raw water flow, not clogged exhaust and I am in salt water where that is for sure common but I never let it get that far (ie changing ex manifolds & elbows every 5/7 years).

 

[kodyman84]

I didn’t have it hooked up to the muffs when I did my exhaust flow test. I had the garden hose hooked up to the outlet hose coming from impeller housing. I definitely didn’t have flow like in the video, but then again I didn’t have the hose cracked open very far either.

i never did pull off the elbows to inspect them or to look for the exhaust flappers. I was waiting on the new manifold to elbow gaskets to come. Coincidently they came today. So I might be doing that tomorrow.

I for sure got the stat installed properly with the o ring to keep it in the upper portion of housing. It was an oem vp stat rated at 160.

Also don’t know if this is related to the overheating issue...but today when we were out I shut it down when I saw it heating up. Opened the cover and waited a good half an hour for it to cool off. I had to run it quick to get back to the dock knowing it would overheat right away. When I got further into the throttle it seemed to sputter a bit and had to back out of it.

 

[Lou C]

Is this a fresh water boat? If so clogged exhaust is not very likely but still worth checking due to the age of the boat (22 years old). It is more likely either you are not getting good flow up from the outdrive to the impeller, or out of the impeller to the t stat housing. Are you sure you got the hoses for the impeller on the right way? If these are reversed on a Volvo it will for sure overheat....There are not that many things that can cause this, that's one...then there's the water tube gaskets in the drive and the water nipple in the pivot housing.

http://www.crowleymarine.com/johnson-evinrude/parts/56685.cfm?mdl=ACBGVC part # 18 water nipple (this is available from Volvo parts sources despite what this says)

http://www.crowleymarine.com/johnson-evinrude/parts/56677.cfm?mdl=ACBGVC
parts #22 and #48 water tube gaskets



http://www.crowleymarine.com/johnson-evinrude/parts/56689.cfm?mdl=ACBGVC
impeller housing, while the water hose fittings look identical, the hoses have to go on the right way or it won't pump.

 

[kodyman84]

I’m pretty certain that the hoses are on properly. When I had them off and was doing my testing I had the muffs on the outdrive and had someone watching those hoses to make sure water was coming out.

As as far whether or not it was a fresh water boat is tough to say. The previous owner, or should I say the seller. He owns the boat storage place that the boat was kept, he was assisting the owners wife in the sale after he passed away. Nevertheless it’s worth the time to pull off the elbows and take a look at them as well as the flappers.

The water tube gaskets along with the nipple would require me to remove the drive for inspection I’m assuming ?

Im also still suspect of the power steering oil cooler being restricted inside. Water goes from the impeller straight to that cooler before going to my stat housing.

 

[Lou C]

http://www.crowleymarine.com/johnson-evinrude/parts/56680.cfm?mdl=ACBGVC

Actually your P/S cooler is on the back of the engine, in line with the raw water intake hose that comes from the transom, then up to the impeller housing. So the impeller has to suck water all the way from the water intakes, up thru the transom mount, then forward to the thermo housing. You would not likely find impeller bits there but if the boat ever was grounded and sucked up sand, there might be sand, rocks, shells etc in there. With an old style Cobra with the drive mounted impeller or a Merc Alpha, same thing, there could be impeller bits in the p/s cooler because their impellers are down stream of the cooler.

In your case I'd see if you can look up Volvo's spec for the impeller output. Put the boat in the water, disconnect the hose from the impeller housing to the thermo housing and just measure it. If its low, then that's your problem. If you had good flow when putting the water muffs on the drive, up at the raw water intake hose that feeds the impeller, them something is wrong with the impeller. Is the belt for sure turning it?

 

[Lou C]

PS I just remembered that Volvo has a PDF called "gas engine overheat diagnosis" you should search around to see it you can find it, it describes all the troubleshooting procedures for overheats. I looked at it and their way of testing is different from OMC and Merc's in that it is based not on volume of water pumped/time, but rather on pressure in the system. The pressure at idle should be about 2 psi and at 3,000 rpm about 10 psi. There is a way to rig up a set up to actually do this but it is a bit involved (as is typical of Volvo). I'd try the OMC method first, hold the impeller to t stat housing up and have some one start the engine, you should see a 2"-4" head of water stream.

Merc says for the belt driven impellers, 7.5 qts in 15 sec.

 

[kodyman84]

Good point! I’ll be looking into all of this either today or tomorrow, whenever the wife will let me get away from the kids for a bit.

I’ll keep you posted on my findings, stay tuned!

 

[kodyman84]

You mentioned that the impeller is upstream of the oil cooler and thus it wouldn’t be possible for the impeller pieces to get stuck in the cooler.

The light bulb just went on for me. I went and checked again and I think my hoses might be switched on the impeller housing. If you are correct about the cooler be behind the impeller.

This is is my hose routing currently:

from the drive to transom
transom to impeller
impeller to oil cooler
oil cooler to stat
stat to water circ pump/exhaust manifolds

 

[kodyman84]

I just checked the diagram on the crawley marine site and also the service manual. It appears that my hoses are correct and hat the oil cooler is downstream of the impeller on my model.

 

[kodyman84]

Well **** now I’m not too sure. Shoot! Maybe I’ll switch them and see what happens

 

[Lou C]

Why not post up a pic of what you have?

 

[kodyman84]

I’m heading back out to the driveway here in a bit I’ll see what I can get pics of.