Replacing Powerhead to Exhaust Gasket?

[mikec]

I need to replace the head to exhaust gasket on my 1992 200xp Evinrude. Im seriously thinking of doing this myself. The engine runs awsome, starts great, great compression, idles wonderfully, but pisses water out the gasket inside the cowling. I have a hoist, a lifting eye, Ive read Clymer's, it doesnt seem all that difficult. Once you disconnect hoses, wires and cables from the head, loosen the nuts that secure the head to the exhaust. Lift the head, remove old gasket, clean surface, install new gasket ($15) install head, thread lock bolts, torque nuts then reconnect stuff. Is there more to it than that or am I overly simplifing the procedure?<br /><br />Maybe 4-6 hours? Any advice would be helpful.<br />Scale of 1-5 with 1=easy, 5=difficult. Im thinking 3. Maybe 2 with beers.<br /><br />I cant wait for my local OMC tech any longer, and am afraid theyll charge me multiple C-notes... YIKES!<br /><br />TIA. <br /><br />-mikec

 

[thirdm]

Re: Replacing Powerhead to Exhaust Gasket?

be careful with those bolts!!!!<br /><br />i haven't done it with a boat engine, but when i changed the exhaust manifold on my jeep engine - i didn't soak the bolts w/penetrating spray or hit them with a hammer. needless to say, i broke one off in the head - which in turn meant my 3-4 hour project turned into 2-3 day project when i had to remove the head to have it tapped out and re-threaded to accept a bolt. also, make sure you apply plenty of anti-seize on those bolts when you reinstall them.<br /><br />if nothing goes wrong: 3<br /><br />hope i could help,<br /><br />mason

 

[Dhadley]

Re: Replacing Powerhead to Exhaust Gasket?

You can lift the powerhead straight up without disconnecting a lot of things. Just make SURE you lift the powerhead straight up off the driveshaft. Cleaning the gasket surfaces usually takes the longest. Disconnect the battery and have at it. As long as you don't break or round off any bolts it should be a 2-3 hour job. <br /><br />Good luck!

 

[ODDD1]

Re: Replacing Powerhead to Exhaust Gasket?

Mike where you from? here in wisconsin a #1 job IS 2 beers....#3 is a 6pack........a #5 is a buddy helpin and the backside of a case.......

 

[mikec]

Re: Replacing Powerhead to Exhaust Gasket?

Im up in Portsmouth New Hampshire, on the seacoast. You know, the Live Free or Replace your Gasket state... with a cold case on hand of course ;-)<br /><br />Thanks guys, Im confident on doing the job now.<br /><br />-mikec<br /> http://www.nesportsman.com

 

[mikec]

Re: Replacing Powerhead to Exhaust Gasket?

Update: Have all the bolts out and just need to hook up the hoist. It was so simple, and anticipate the remainder of the job to go smoothly. Bolts came out easily and only had to disconnect the shift rod, the tilt switch, a vac*** line and the tell tail. BTW: The marina over the phone implied it would be an all day job.. HA! anyone going thru NH for vacation, stop by, Ive got an extra $400 to spend on bee-ha!

 

[Dhadley]

Re: Replacing Powerhead to Exhaust Gasket?

Congrats! Thanks for the update and invite.

 

[mikec]

Re: Replacing Powerhead to Exhaust Gasket?

One more ? - Shes all buttoned up and runs beautifully, but I want to be sure about one more item, if its not too late - torque on the bolts... I have 2 manuals, and neither is very clear. They both say 20ft/lbs on the head to exhaust housing adapter bolts, and in the next paragraph it say 140ft/lbs on the head to exhaust housing bolts. The bolt torque chart says the same. Man, talk about unclear! This is what I did, the 8 smaller length bolts/nuts that are more associated with the gasket and go into the head I put at 20ft/lbs. And the 6 long larger bolts that are on each side of the exhaust housing and eventually go up into the head are at 140ft/lbs. Is this correct? I hope. That 140 sure is alot.<br /><br />TIA, you guys are a great resource.<br /><br />-mikec

 

[Yepblaze]

Re: Replacing Powerhead to Exhaust Gasket?

I think they are saying or meaning to say inch/pounds

 

[mikec]

Re: Replacing Powerhead to Exhaust Gasket?

thank you, guess i need glasses. sorry to take up the bandwidth.