The unfixable headgasket - 1996 Force 15hp

[Flanagani89]

Hey all

New to the forum and boats in general.. Hope you guys can give me some insight, I'm close to losing it on this thing

The impeller went the third time I took out my new to me force outboard, resulting in the motor getting quite warm, and myself having a very long day getting it back to the launch. Noticed that the head had a very small leak.
The impeller was swapped out. Head gasket was ordered, I was thinking this was going to be a simple fix.
New gasket goes in. I ordered the manual so I had the torque sequence (didn't have an inch-lb wrench though). Water was now gushing around the gasket.

Second head gasket ordered. Figured I was an idiot and didn't check to see if anything was warped. Feeler gauge showed that the block was good.. head was slightly warped, so I did the sandpaper trick and got it pretty good. Second gasket put it, fired it up and... it still leaked
Ordered a new head. While I was waiting I tried a third gasket, this time with some sealant. Huge improvement, but still leaked.
... got the new head in. Put it on without the gasket and it looked super snug on the block, no gaps whatsoever... Put the fourth gasket on (this time with new bolts!) Torqued what bolts I could get to and you guessed it, still leaking.

I feel like I'm missing something obvious here. The only thing I can think of is the gaskets being faulty? They are Serria replacements. I have a fifth one coming.

Thoughts?

 

[jimmbo]

Welcome to iboats

What pattern are you using when torqueing the Head Bolts?
When it comes to Lapping a Head, Close, isn't good enough. Curious, what grit did you use?
Recheck the Block where the Gaskets go, for trueness. You say the new Head fit snug, with not visible Gaps, well you can't see the surfaces where the Cylinder Wall and the head meet.
Are you ordering the correct Gaskets? Have you removed all of the old gasket and sealer from the Block and Head?

 

[Flanagani89]

This is the pattern I'm using.
Edit- couldn't upload picture., enjoy this drawing

And I believe I used 80 and 100 grit with the old head. Both the head and the blocked was cleaned before I put a new gasket in.
The gasket is the only one available it looks like.. A buddy told me he had an issue once with a replacement gasket being too thin, which makes me somewhat concerned

 

[jimmbo]

This is the sequence I've used


What is the Torque Spec?
If it is, say, 18ft lbs, Are you doing 18lbs from the get go, or are you doing 10 lbs, then once all are done, you go over again with 15lb, and then again with 18lbs, and then a 2nd time at 18?

 

[Flanagani89]

Interesting I'll try that one on the next gasket, and it's 130 inch pounds. I couldn't get the torque wrench in on the bottom three bolts but I tried my best to match the other 5.. As for torqueing them I did started them at 70 inch pounds then went to to 130

 

[Nordin]

Do the torque in three steps and in a circular pattern as jimmbo describes.
If the end value is 130 inch pounds start with 70 in first step then 100 and then finish with 130.

 

[Jiggz]

Another thing to look for also is to make sure the gasket does not slide down before you are able to hand tighten at least two bolts. There is a little slack on the size of the bolt holes on the gasket that if just laid vertically can slide down leave a gap in the water jacket holes. I use masking tape to hold the gasket in place perfectly aligned with jacket and cylinder holes and then hand tight top and bottom bolts and then remove the tape. This ensure perfect alignment of the gasket. Unless, you have 2nd set of hands that will hold it for you which is even better. Or fully tilt the motor so the head is not fully vertical.

 

[Flanagani89]

Appreciate the reply guys, Jiggz I definitely didn't do that, I'll make sure to watch out for the slack this weekend. And I'll try the three step torqueing... Anything I can buy that will allow me to get a torque wrench on those bottom three bolts?

 

[jimmbo]

Anything I can buy that will allow me to get a torque wrench on those bottom three bolts?

The Gasket that goes between the Block and the Mid Section.

BTW, 100 Grit is quite Coarse as a final finish on any future Truing of Surfaces.

 

[Jiggz]

Appreciate the reply guys, Jiggz I definitely didn't do that, I'll make sure to watch out for the slack this weekend. And I'll try the three step torqueing... Anything I can buy that will allow me to get a torque wrench on those bottom three bolts?

Search for torque wrench adapters which will allow you to torque bolts in tight space either with an open wrench or box wrench.

 

[Flanagani89]

The Gasket that goes between the Block and the Mid Section.

BTW, 100 Grit is quite Coarse as a final finish on any future Truing of Surfaces.

You mean pulling the top of the motor there?

 

[jimmbo]

Removing the Powerhead will give you complete access to the lower bolts. Someone mentioned adapters, but they can affect the amount of torque that gets to the bolt, and/or the amount of Torque you need to apply

 

[Flanagani89]

Removing the Powerhead will give you complete access to the lower bolts. Someone mentioned adapters, but they can affect the amount of torque that gets to the bolt, and/or the amount of Torque you need to apply

I'll see if I can get ahold of a gasket before this weekend

 

[Joe_the_boatman]

Following this thread - I'm having the exact same issue with my new-to-me 1990 Force 5hp.

Replaced gaskets (dry, no sealant), lapped both head and powerhead (180 grit on glass, crosshatch), NEW head (Quicksilver), new head bolts.

STILL leaks water!!!