achris
More fish than mountain goat
- Joined
- May 19, 2004
- Messages
- 27,468
Previous thread that started over 2 years ago with this problem. Click HERE
After a couple of years of chasing this problem I believe I may have found my problem.
Brief history: Purchased the engine new Nov 2006. In May 2009 (engine hours - 150) it developed an oil leak from the bottom of the timing cover. On removal of the sump I found a crack in the bottom edge of the plastic timing cover. As the engine was out of warranty Mercury Marine wiped their collective hands of me. Not even offering a repair method that would solve the problem. I replaced the timing cover thinking it was just a one off failure. 8 months later the engine leaks oil again. This time I look a lot more closely at the timing cover and sump and notice that the sump was deformed where the cover was cracked. I filed the raised area down and fitted a new oil pan gasket with sealant and hoped for the best. That one lasted just over 12 months, and then started to leak oil again. This time I had had enough and decided to take it back to the dealer for him to sort out. He quoted $3,000, which included 7 hours to fit a new timing cover and sump, and 6 hours to drop the engine back in the boat (it takes me less than 2 hours without breaking sweat!). On inspection the leak appeared to have come because of a lack of sealant, not a cracked cover. So I loaded the gasket with sealant and refitted it all. That was in June 2011. It leaked again 2 months later. I removed the engine (I just whistle now and it jumps out by itself) and found the cover cracked in 2 places, the result of too much sealant putting excess pressure on the unsupported area of the timing cover. I put yet another new timing cover on and was really careful with the sealant and put it all back in the boat.
Bearing in mind that each time I have done this work it has been from underneath the engine while it has been suspended on a chain block.
Took the boat out for a test run, confident that all was well, and it was, for about 20 minutes. Lots of oil coming out! This is getting silly. I pulled the engine, again and this time decided that I would do it differently. I have modified an existing engine stand so I can rotate the engine and work on the sump. See the photo of the ?engine rotisserie?. I didn?t like the idea of 650 lbs of fully assembled engine hanging on 4 bolts in the back of the flywheel housing. I have built a frame that the engine mounts into and it supported at both ends. Spinning the engine over it easy and very comfortable, without the engine just hanging by its back end. I was cutting and welding for about 7 hours to fabricate the frame, and I?m more than happy with the result.
When I took the sump off, this time working from above it, I noticed that the oil pan gasket was sealed perfectly. On very close inspection I have found an area each side of the timing cover that was not being sealed. See red arrows in the photos.
I will be sealing it up and putting back together, this time in such a manner that I can see what I?m doing?. I will keep this thread posted with the result. Hopefully, after 2 years and 4 timing covers?
Cheers, and to all of you out there who own V6s with a plastic timing cover and an oil leak, there is hope!
Chris????
After a couple of years of chasing this problem I believe I may have found my problem.
Brief history: Purchased the engine new Nov 2006. In May 2009 (engine hours - 150) it developed an oil leak from the bottom of the timing cover. On removal of the sump I found a crack in the bottom edge of the plastic timing cover. As the engine was out of warranty Mercury Marine wiped their collective hands of me. Not even offering a repair method that would solve the problem. I replaced the timing cover thinking it was just a one off failure. 8 months later the engine leaks oil again. This time I look a lot more closely at the timing cover and sump and notice that the sump was deformed where the cover was cracked. I filed the raised area down and fitted a new oil pan gasket with sealant and hoped for the best. That one lasted just over 12 months, and then started to leak oil again. This time I had had enough and decided to take it back to the dealer for him to sort out. He quoted $3,000, which included 7 hours to fit a new timing cover and sump, and 6 hours to drop the engine back in the boat (it takes me less than 2 hours without breaking sweat!). On inspection the leak appeared to have come because of a lack of sealant, not a cracked cover. So I loaded the gasket with sealant and refitted it all. That was in June 2011. It leaked again 2 months later. I removed the engine (I just whistle now and it jumps out by itself) and found the cover cracked in 2 places, the result of too much sealant putting excess pressure on the unsupported area of the timing cover. I put yet another new timing cover on and was really careful with the sealant and put it all back in the boat.
Bearing in mind that each time I have done this work it has been from underneath the engine while it has been suspended on a chain block.
Took the boat out for a test run, confident that all was well, and it was, for about 20 minutes. Lots of oil coming out! This is getting silly. I pulled the engine, again and this time decided that I would do it differently. I have modified an existing engine stand so I can rotate the engine and work on the sump. See the photo of the ?engine rotisserie?. I didn?t like the idea of 650 lbs of fully assembled engine hanging on 4 bolts in the back of the flywheel housing. I have built a frame that the engine mounts into and it supported at both ends. Spinning the engine over it easy and very comfortable, without the engine just hanging by its back end. I was cutting and welding for about 7 hours to fabricate the frame, and I?m more than happy with the result.
When I took the sump off, this time working from above it, I noticed that the oil pan gasket was sealed perfectly. On very close inspection I have found an area each side of the timing cover that was not being sealed. See red arrows in the photos.
I will be sealing it up and putting back together, this time in such a manner that I can see what I?m doing?. I will keep this thread posted with the result. Hopefully, after 2 years and 4 timing covers?
Cheers, and to all of you out there who own V6s with a plastic timing cover and an oil leak, there is hope!
Chris????
