2015 PCM ZR409 - Exhaust Manifolds - Overheating
Printed From: CorrectCraftFan.com
Category: Repairs and Maintenance
Forum Name: Engine Repair
Forum Discription: Engine problems and solutions
URL: http://www.CorrectCraftFan.com/forum/forum_posts.asp?TID=50952
Printed Date: April-25-2024 at 5:05am
Topic: 2015 PCM ZR409 - Exhaust Manifolds - Overheating
Posted By: scotchipman
Subject: 2015 PCM ZR409 - Exhaust Manifolds - Overheating
Date Posted: October-17-2022 at 4:39pm
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My 2015 ZR409 exhaust manifolds are overheating then my boat goes into some kind of limp mode. My ZR409 has coolant in the engine block and fresh water in the manifolds with a heat exchanger in the rear. No engine light is coming on and the water temp is reading normal. What I think is happening is the exhaust manifolds are getting clogged up? When I pull the plugs on the manifolds I get a lot of debris coming out with the water that looks like silt or hard water that has been baked onto the inside of the manifold then has flaked off. This is the second time this has happened, the first time was only about 20 hours prior. Do you think I'm correct in assuming that the overheating is due to the manifolds getting clogged? If so is there anything I can do beside pulling the four plugs and removing the debris? Could my issue be something completely different and if so what can I check? |
Replies:
Posted By: Jonny Quest
Date Posted: October-17-2022 at 4:47pm
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Check your email…. ------------- Current 2003 Ski Nautique 206 Limited Previous 2001 Ski Nautique Open Bow 1994 Ski Nautique Open Bow Aqua skiing, ergo sum |
Posted By: scotchipman
Date Posted: October-17-2022 at 5:21pm
| Thanks, got it! |
Posted By: TRBenj
Date Posted: October-17-2022 at 8:59pm
| Bleed the system? |
Posted By: KENO
Date Posted: October-18-2022 at 8:09am
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Did Jonny cure your problem? You should probably take the shotgun approach and post this question everywhere you can think off and give a little more info too  Does a Centurion have the same instrumentation and alarm package that CC had that year? What happens to your engine in this "limp mode" ? |
Posted By: Jonny Quest
Date Posted: October-18-2022 at 12:37pm
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Scot is a long-time friend and lives nearby. I offered to have him bring the boat over and we can do a more thorough evaluation. JQ ------------- Current 2003 Ski Nautique 206 Limited Previous 2001 Ski Nautique Open Bow 1994 Ski Nautique Open Bow Aqua skiing, ergo sum |
Posted By: Hollywood
Date Posted: October-18-2022 at 2:30pm
| What does the engine manual say? Most of them have a basic troubleshooting/diagnostic section. Is exhaust manifold temperature even monitored/mentioned? |
Posted By: KENO
Date Posted: October-18-2022 at 5:28pm
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2014 owners manual in the link. Doubt there's any difference http://www.planetnautique.com/CorrectCraftManuals/2014/PCM-14.pdf" rel="nofollow - link Some info on page 58 (and a few other pages too)
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Posted By: scotchipman
Date Posted: October-19-2022 at 3:47pm
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I used the boat yesterday with no problems, pulled 8 sets. I'm not sure if Centurion has the same alarm package as CC for 2015 but no alarm is going off or engine light coming on. When it goes into limp mode you can only idle the boat back to the dock, I won't power up back on plane. I really think it is just a matter of keeping the exhaust manifolds free of the flaking debris, for whatever reason several of us that use our boats a lot exclusively at our lake are having the same issue. Our lake has around 1,000 ppm of dissolved solids in addition we have a lot of very fine sediment. I plan to drain the exhaust manifolds more often and will see if I can run some fresh water through the system from time to time, hopefully this works. If not I will have to pull it out of the water and have Jonny look at it closer. |
Posted By: Tim D
Date Posted: October-19-2022 at 5:20pm
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What's the ph level of the lake water? ------------- Tim D |
Posted By: KENO
Date Posted: October-19-2022 at 5:58pm
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Do you have an Orange/Amber "service engine soon": indicator? It's for exhaust issues on the catalytic converter engines That would come on for an Exhaust Manifold Water Temperature high condition at about 220 degrees and in PCM's words the engine would derate itself.. There's also the Red "check gauges" indicator for engine related issues I'd probably be talking to a Centurion dealer because it doesn't seem logical at all to go into a limp or protective mode without some indicator or horn being activated Not going above idle is more of a "crawl home gasping for your last breath" mode than the typical limp mode.
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Posted By: scotchipman
Date Posted: October-20-2022 at 1:19am
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The PH level is 8.5. No warning lights of any color are coming on. Limp mode may have been the wrong description. Both times when it has happened I was skiing and not driving, I had the driver just idle back to the dock but the driver reported a significant loss in power which I definitely noticed while skiing. |
Posted By: KENO
Date Posted: October-20-2022 at 7:44am
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I get the impression from reading your thread on Centurion crew that you might think the catalytic converters have water flowing through them. The only thing flowing through them is exhaust gas with a water jacket around the gas side. I think the derate starts at 220 degrees and if it keeps going up to 225 it derates more. Have you checked the manifold temps with an IR gun? If it was my boat, I'd be finding out more about the protective system and instrumentation, but it's not my boat, ....... it's your boat . A dealer or PCM can tell you somethingWhat are the guys with the other boats with the same problem doing?
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Posted By: Tim D
Date Posted: October-20-2022 at 9:46am
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Does the boat have the garden hose attachment on the back for flushing? If the sun dries out the cap/cover a small crack in it can let air be pulled in the system. ------------- Tim D |
Posted By: scotchipman
Date Posted: October-21-2022 at 1:42am
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Good to know there is no water flowing through the catalytic converters, I should find a diagram of the inside of the manifolds. I have not checked the manifolds with a IR gun. The two times they have overheated you could smell them and when I dripped water on them from my wet gloves it would quickly boil off.
A 2015 ish 200 with a 6.0 just had the manifolds and a few other parts replaced for $6k, a 2008 196 with a 5.7 had the manifolds replaced as well for a much more reasonable cost. Other owners are draining/cleaning them out like me. I heard one owner took his to the car wash and shoved the power wash wand up the drain plug hole in and attempt to clean. The owner with the 196 just bought some starbright descaling engine flush he is going to try. I have talked to a few PCM dealers and they are not helping much, they say bring it in and if we can duplicate it we might be able to fix it. No garden hose attachment for back flushing on my boat currently but may put one on to run fresh water through the system from time to time. |