Mercury 1150

[laganiere]

Hi,
I am trying to replace the cover where the spark plugs go in but I have already broke 2 bolts off.is there any way to get these loose without breaking any more, and any suggestions on getting the broke ones out or would the 2 broken ones be fine to ignore, they are not next to each other? this is a replacement power head and I think it might have been n used on salt water. I also think that they were over tightened, around all the bolt holes are stress cracks, would out hurt to just leave the cover on, the cracks are around 3 or 4 bolt holes.

 

[Bob_VT]

Re: Mercury 1150

Are you referring to the water jacket cover? Most of those bolts are a PITA however..... you should be able to get nuts on the backside if you break one off. Look at the cover and you will understand.

 

[laganiere]

Re: Mercury 1150

Its the cylinder block cover.its where the spark plugs go in.there is no way to get nuts onto the bolts

 

[backyard mechanic]

Re: Mercury 1150

Can't recall any 1150 Mercs that had a water cover without nuts and bolts . No matter... if the bolts break off you will need to drill them out and try to EZ out them. As with any salt water engine the water cover bolts will be corroded and need to be GENTLY removed. Try heat, solvents etc. Don't force them. Work the bolt back and forth if you can. The more it gets free the easier it gets.

Welcome to a mechanics nightmare!

 

[Bob_VT]

Re: Mercury 1150

If we are talking about an inline........ the water jacket bolts surround the outer perimeter and there is room if needed to re-install a nut behind. Look at post #26 here http://forums.iboats.com/showthread.php?t=394536&page=2

 

[laganiere]

Re: Mercury 1150

hear are some pics

 

[laganiere]

Re: Mercury 1150

would it be easier to put helicoils in, or spend forever trying to loosen these bolts?

 

[Bob_VT]

Re: Mercury 1150

You do not need to helicoil.

That water jacket cover is going to need major repair or replacement. You might find someone who can weld up those cracks then re-surface the back side or you may not get a good seal.

Here is an option you can try if you want..... grind off the bolt heads and lift off the cover then you will have access to the rest of the bolt and apply some LIGHT heat (do not melt the aluminum to remove the remaining portion.

If you shear off a bolt you can drill it and when you re-assemble use stainless steel bolts and NUTS........ there is room for a nut where I have circled

I have been there and done that....... it can be done

 

[laganiere]

Re: Mercury 1150

I have a new cover for it my people is that all of the bolts are breaking.i noticed a couple areas where you can't get a nut on the bottom.any suggestions for those, taping them maybe?

 

[JimbC]

Re: Mercury 1150

laganiere, Hey Bud I know your pain. :facepalm: I went through all this, ended up having to find a new cover because the other was breaking off ears. I think all my bolts broke off but like 3 or so. It was a pain. I also started drilling and tapping the old ones out only to have the tap break off in one. To answer your PM no I never used the helicoil I have been sidetracked and havent done anything else to my motor. I do need to get back to work on it though. You might want to check this out, I got the info for them on here somewhere. These are way way better than using helicoil. http://www.timesert.com/

 

[Chris1956]

Re: Mercury 1150

Try some heat and then spray with penetrating oil (PB Blaster is good). Then put a hand impact driver on the bolt head and smack it gently. Concentrate on the fully tapped holes on the bottom as they have no way to put a nut on the backside of the bolt.

 

[arsenalpsu]

Re: Mercury 1150

Yes replace that cover. I got lucky replacing mine- not one broken bolt! I bet yours was leaking and instead of pulling it off and replacing the gasket the old owner just tried to tighten the bolts more. When you put a new one one use some black ATV silicone, it will help seal her up. For the bolts, not all models have nuts behind them, the "newer" ones just screw into the block, drill yours out and put a nut behind it. Don't just leave one out as it will eventuially leak. You may get lucky if your bolts broke off at the head you can grab them with an wrench when the cover is off and back them out. They'll be sticking out between 1/4-1/8".

 

[Mi duckdown]

Re: Mercury 1150

Buy some Left handed drill bits. Goto this site
www.asashop.org/autoinc/may2003/techtotech.htm

 

[Bob_VT]

Re: Mercury 1150

No the nuts "can" be installed if a bolt breaks and needs to be drilled out........ it is the future of the repair....... avoids tapping to an oversized bolt.

 

[laganiere]

Re: Mercury 1150

Yes I have a new cover I am going to weld some nuts on and see if that works.they all broke except for 2 otherwise I will bolt them on.there was only one spot where you cannot get a nut in. but that one came out, thank god. Should I use stainless steel or what grade Steel should I use? If I get them screwed should I use antiseize on them?

 

[Bob_VT]

Re: Mercury 1150

Do not weld nuts to anything. Stainless steel bolts from your local hardware store will work fine and if applied clean and dry you should be fine....... you could put a dab of neverseize on the shank by I would avoid the nut. Grease and neverseize create a situation where people over tighten or over torque which then cracks the cover.

 

[laganiere]

Re: Mercury 1150

Anyone know the torque specs for this and is there a pattern to follow

 

[Chris1956]

Re: Mercury 1150

use 85 inch pounds for the 1/4-20 bolts. 5/16 bolts water jacket cover bolts use 150 inch pounds. Torque sequence is from the center of the cover out. Specifically, first tighten all bolts in the center of the cover, then move down 1 bolt and tighten all those bolts, then move up to 1 bolt above the center and tighten those , then two bolts down from center and tighten them. Continue until done.

 

[laganiere]

Re: Mercury 1150

Thanks, there are 15 7/16 bolts for the cover

 

[Chris1956]

Re: Mercury 1150

I think you are confusing the size of the wrench with the size of the bolts. A 7/16" wrench generally fits a 1/4" bolt. Measure a bolt diameter with a ruler or caliper