So how do you stop the poppet valve from leaking out of the weep hole???

[Ron V]

Hey guys, second kit in as many years and it's doing the same thing. 2005 Merc 2.5 150. Both kits were GLM kits. Not a lot of information out there, including on this site. Yes, the screw is seated all the way into the end of the valve. One bit of information that I did find was that the OLDER motors (not mine) used thinner gaskets than what comes with the rebuild kits, and that the thicker gaskets will keep the ridge on the diaphragm from seating properly on the underside of the cover. Any other ideas? I ran it all last year with it leaking at idle.

Otherwise I'm going to tap that hole out for a tiny fitting, connect a small hose to it, and route the hose down through the cowl drain. :D

Thanks.

[XstreamVking]

What is a glm kit? Sorry not familiar with that one.... Either the dia has a hole or is not seating. Some use a plastic washer and can be changed over to a larger ss washer to help the dia seat better.

[FUJIMO]

stream, GLM is simply an aftermarket vender name, like Sierra, etc. They started years ago by offering/selling merc water separator filters & they expanded from there into lots of other parts & "kits".

[Jay Smith]

Remove ALL poppet parts bead blast inner housing , make SURE donut is seated in block with a sharp punch peen the female block metal over the donut , insert the rubber inner part where plunger works , make sure all surfaces where the diaphragm seats is clean and flat , I use the pro Marine poppet kits and order the poppet gaskets separate as the ones in the kit sux , I apply thin coating of loc tite 518 gel seal around seating area and diaphragm, I also apply thin coating on the two gaskets shouldn’t leak , most of the time if it leaks out the weap hole you have over pressured the diaphragm, if your using house hose pressure it will over pressure and leak !! But motor water pump won’t do it....Outboard motor water pressures can get 18 psi your residence can get 60 psi that diaphragm will not contain that extra pressure so it bleeds excess out that weep hole ...

Jay

[David L]

https://www.boats.net/catalog/mercury/outboard-by-year/mercury-race-outboard/2002/1922302zh/exhaust-divider-and-exhaust-plate

Another tip along with the great advice above:

Make sure screw (#12) which threads into (#20) is nice and snug. Providing that this illustration is the same as yours?

Had a weep issue on mine once and ended being the screw was a tad loose.

[Merc 2.5]

Glm is know as good luck marine. Not quality parts

[RSWORDS]

Listen to Jay and buy better parts. Mercury or pro marine

[Michael J Giesler]

Hey Ron v very simple solution put a 280 on it no poppet valve needed lol I hope things are well buddy

[Ron V]

Hey guys, thanks for the input. The house hose was registering about 11-12 psi on the gauge through the flushing port. Checked to make sure the screw was snug and reassembled with Permatex #2 around the edge of the diaphragm and on gasket between the inner and outer plate. Let it set overnight and retorqued it. Leak tested it on the hose and it seems fine now. Will lake test it as soon as weather allows.

Mike - that was Plan B!