98 115 powerhead rebuild mistake

[GatorMike]

When I rebuilt my powerhead a month or so ago I obviously made a mistake. I don't think it is a major screw up but will for sure mean removing the powerhead and reseating it. I think there is a possibility I may have to do more than just replace the gasket the powerhead sits on but I am not real sure. Let me explain the problem I have first then I will tell you how I think I may have screwed up.

I'm going to refer to a diagram to explain the problem. http://www.crowleymarine.com/johnson-evinrude/parts/25128.cfm
My cooling system seems to be operating fine but the other day I noticed when I throttle up I have a steady stream of water flowing out of the top of part #20 (steering arm & shaft) the stream of water is comming from just under where the number 73 on that diagram is located, at the rear of the steering arm. It flows steady when throttled up but doesn't flow at all at idle.

My first thought was that the leak was where the powerhead seats on gasket #18 in the following diagram. http://www.crowleymarine.com/johnson-evinrude/parts/19408.cfm
However I am not sure. When I had the powerhead off I removed some bolts that might also have caused the problem. When I pull the powerhead and reseat it I would not be a happy camper if that does not take care of my problem.

Back to the original diagram.
http://www.crowleymarine.com/johnson-evinrude/parts/25128.cfm
While my powerhead was at the machine shop being bored I did some cleaning on the engines midsection. I removed 3 bolts #s 28 & 20 and plate #35. I replaced them and retightened them but was wondering if there might have been some sort of a seal I might have broken in doing so? I am not sure what those bolts screw into and can't really tell from the diagram but if they screw into part #23 I could see where gasket #40 might be the leaking culprit?

I know this is confusing I just want to make sure when I pull the powerhead again and reseat it I am fixing the problem.

 

[jonesg]

Re: 98 115 powerhead rebuild mistake

Never been there but #73 is a seal, if it got cocked and isn't sealing thats all it takes. No matter what, you're in for a dime in for a dozen, its got to come off. At least you know where to start looking.

 

[GatorMike]

Re: 98 115 powerhead rebuild mistake

I knew I was going to confuse someone. The water is not comming from under part #73 but comming from the area under where the number 73 is. Actually I don't even know that is where it is comming from that is just the first place I can see the stream of water.

 

[daselbee]

Re: 98 115 powerhead rebuild mistake

GM, I think you are barking up the wrong tree regarding the base gasket leaking, and especially the two bolts and plate that you referred to. Those bolts just hold the plate that holds the upper mount in place. There is no sealing going on there.

If it were me, I would look for a wrinkled or mis-seated water tube grommet, either the upper or the lower. I think your midsection is filling with water pump water, and overflowing when pump is outputting in high volumes.

I would pull the lower, hook a hose directly to the water tube and inspect (with a flashlight) the upper grommet for a massive leak. Then look over the condition of the lower grommet. It is best to grease the grommet when assembling, and be sure you have it in the right side up. It only goes one way. You will see that it is tapered.

If all that checks out first, then you are set to pull the p'head for an exhaust adapter inspection.

 

[GatorMike]

Re: 98 115 powerhead rebuild mistake

Thanks daselbee, sounds like you may have saved me some work. I am familiar with the gromlet at the lower end of the water tube but can't ever remember seeing the upper end. Can that gromlet be replaced from below?

 

[daselbee]

Re: 98 115 powerhead rebuild mistake

Unfortunately not. If the upper grommet is trashed, you have to pull the p'head and disassemble the exhaust adapter to get a new grommet in.

But don't fly off and start tearing the engine down. I assume you remove the lower anyway to eventually remove the powerhead. (I was told that was the correct way). So inspect carefully after you get the lower off.

I bought a 3 foot piece of clear plastic 5/8" tubing, put a female garden hose fitting on one end, and hose clamp on the other. You can slide it up on the water tube, clamp it, hook a hose to it, and run your engine with no lower unit installed if you want. I do it all the time. That might tell you something, as well as a good inspection while the hose is on, but without the engine running.

 

[GatorMike]

Re: 98 115 powerhead rebuild mistake

OK I droped the lower unit after work today and put a garden hose on the water tube. My garden hose was a tight fit, didn't even need a hose clamp. Anyway I turned on the water and had water flowing out of 3 places. Had water coming out of the exhaust housing, had a steady stream out of the Pee hole (Telltale) and had the steady stream of water coming out from around the steering arm. I know that can't be normal. I couldn't see up to the top of the water tube so I have no idea what is happening up there.

I guess sometime in the next couple of days I will be pulling the powerhead, I may be looking for some guidance when I do. I understand how the waterpump works and the flow of water through the engine block but I have never been able to figure out the waterflow out of the top of the water tube since you can't see the top of the tube and I have never had the midsection apart. If the problem isn't the gasket between the midsection and the powerhead I am going to be lost.

My repair manual really doesn't detail the water flow through that part of the motor. Does anybody know of any diagrams that would help? Thanks.

 

[walleyehed]

Re: 98 115 powerhead rebuild mistake

Is the stepped rubber grommet IN-PLACE on top of your shift-shaft box housing where the shift-shaft comes up???? Do you have a lower unit speedo tube pulled in 2???

 

[jonesg]

Re: 98 115 powerhead rebuild mistake

Use a strong flashlight to check out the water tube seal.
Bend over and look up.!

 

[GatorMike]

Re: 98 115 powerhead rebuild mistake

Is the stepped rubber grommet IN-PLACE on top of your shift-shaft box housing where the shift-shaft comes up???? Do you have a lower unit speedo tube pulled in 2???

No lower unit spedo. I am not sure what you are talking about on the shift shaft grommet, I am only seeing one gommet on the shaft. Looks like from the diagram there should be 2 but I am not sure where the 2nd one would go. Does it just sit on top of the 1st one?

 

[GatorMike]

Re: 98 115 powerhead rebuild mistake

Use a strong flashlight to check out the water tube seal.
Bend over and look up.!

OK, I looked for it last night but maybe my flashlight wasn't strong enough, I'll try again when I get off work.

 

[jonesg]

Re: 98 115 powerhead rebuild mistake

Do it after the sun goes down, ambient sunlight makes it harder to peer into darkness.