Water squirting from between crankcase and exhaust housing

[anauburnfan]

I recently purchased a 1988 Johnson 200. It runs fine on hose at any speed or on water once in gear above idle. It is difficult to crank in water and idles rough with regular miss and stall at idle -- usually when trying to dock... Anything above idle it runs great. I noticed that there is water coming out from between the bottom of the crankcase and the exhaust housing at midsection. On the hose, this is more like a leak, when in water, it is squirting out. It is on the starboard side just above the fitting for the tubing that eventually reaches the telltail. Is this a major concern, and could it be related to my idle problem? There is also a lot of fuel oil that leaks down the outside of the midsection. I cannot locate the source of this leak, but it appears to be coming from the fore side of the intake manifold though the carbs do not seem to be leaking. When I mentioned this to the boat shop that sold the motor, he indicated that it is probably just the carb bowls leaking and that I should store the motor upright (not tilted). I told him about the rough idle problem and he said it was probably due to gunk in the carbs because the boat sat for ten years between old motor and this one. He said I should bring the motor I bought from him in to have the carbs cleaned again. It has 2 spin on fuel filters in series, so I dont see how tank crud (which I have no doubt exists) could be making it to the carbs. Am I incorrect in thinking this? The second spin on has a clear bowl with water separator and no tank crud shows up there, though the first filter definitely has crud and I have changed twice in addition to adding a clear in line pre filter. Thanks for any advice on this long post.

 

[Haffiman]

Re: Water squirting from between crankcase and exhaust housing

At a minimum you would probably need to lift the powerhead to change the gasket to stop the water leak.
As for fuel/oil leak, should be NO leak!!!
It may get down to under what 'conditions' (warranty) you bought the boat.

 

[anauburnfan]

Re: Water squirting from between crankcase and exhaust housing

Unfortunately, I did not purchase the boat with the motor, just the motor. So I can see how it would be easy to claim the boat fuel tank is the source of the problems as it relates to idle. The clear in-line prefilter confirms that there is certainly a fuel tank contaminant problem. I am hoping that with time and several filter replacements that this will eventually become less and less of a problem. However, I am concerned that by the time the fuel tank problem is fixed that any complaints to the seller about the motor would be less and less credible. Thanks for the reply.

 

[Van Wildonher]

Re: Water squirting from between crankcase and exhaust housing

I'm having a hard time imagining where your water leak is.. if it is between the head and the midsection, how can it be above the fitting for the tell tale?

Also, where is the fuel/oil running down the midsection? Do you see it coming out of the carbs and running down, or is it just down around the prop/exhaust?

 

[tashasdaddy]

Re: Water squirting from between crankcase and exhaust housing

is the leak between the cylinder block and the midsection, or the gear case and the midsection. this makes a big difference.

it could be coming for several place is block to midsection. tstat hoses, tales routes, base gasket, cylinder head, cracked block.

 

[anauburnfan]

Re: Water squirting from between crankcase and exhaust housing

The water leak is starboard side well aft between crankcase and exhaust housing. Just a little above the lower motor cover. Dribbles out when running on hose, squirts out when in water. I assume there is a bad gasket there, but did not know if this would affect the idle.

I cannot figure out where the fuel/oil leak is originating. It does not appear to be coming from carbs, but does seem to coming from somewhere on the front side of motor like beneath the intake manifold. I cannot see under there very well. It eventually drips down through the lower motor cover and down the outside of the mid section. Not just near prop/exhaust.

 

[winfieldh]

Re: Water squirting from between crankcase and exhaust housing

Hi,
I am by no means a mechanic, but do have a '92 Johnson 200 that had similar issues to what you're describing.

The rough idling was sourced to old/loose hose clamps in the fuel system. I started poking around one day and there were at least 3 of the plastic squeezy type clamps that "looked" great, but in fact were loose. Once those were fixed the "sneezing" and rough idle went away.

I also had gas/oil mix running down lower unit on occasion. What I discovered was it was due to carb floats sticking. I could take a rubber mallet and tap the carb bowls to loosen them up and all was good. So a friend and I took them apart, cleaned them, and have been good since.

The water leak you describe is hard to picture, but I also had a leak between what I would call the power head and lower unit. There was a metal gasket that had been 'pouched' out and when running water would drip out. Since it was just a drip I did what every cheap skate boat owner would do. Sanded it down and put a coat of JB Weld over top of it. Dry as a bone since. Like I said, it was really just a drip, no force at all so I figure the goo would work to hold the water in. So far, so good.

Remember, no mechanic here, just tales of past experience. Take with grain of salt.

Cheers,
Winfield

 

[anauburnfan]

Re: Water squirting from between crankcase and exhaust housing

Thanks for the tips. Were the fuel leaks you found on the boat or motor side? I have replaced all the lines between tank and motor. The small ones that feed the carbs I have not messed with. I don't see any leaks associated with them. They do look like they would be difficult to get tight on all those tiny little plastic tees and other connectionz

 

[tashasdaddy]

Re: Water squirting from between crankcase and exhaust housing

use the fuel line zip ties, on them. leak could be from pulse line into the block.

 

[anauburnfan]

Re: Water squirting from between crankcase and exhaust housing

I have not had a chance to check the pulse line - should be able to tomorrow evening. If it is hidden on the front side of the block somewhere it is likely the source of the fuel leak though I am guessing it might be hard to see/get to. I am picking up some zip ties today. I assume there should be one on every tube connection? I don't recall if all the lines inside the motor cover have them now.

Could either of these two leaks (water or fuel) be the cause of the poor idle/stalling when in the water? If not, is the water leak at that connection from the crankcase to the exhaust housing adapter a serious concern? Looking at the midsection parts diagram on evinrude website for j200txccr my leak is right above the elbow identified as #35 part #0321886. I'm guessing if water is shooting out from that gasket it could be shooting in as well or would another section of the gasket have to be messed up for that to happen. If water is leaking into the exhaust could that be pulled back into the cylinder?

Thanks again

 

[winfieldh]

Re: Water squirting from between crankcase and exhaust housing

Thanks for the tips. Were the fuel leaks you found on the boat or motor side? I have replaced all the lines between tank and motor. The small ones that feed the carbs I have not messed with. I don't see any leaks associated with them. They do look like they would be difficult to get tight on all those tiny little plastic tees and other connectionz

I'm afraid the ones I found were on the motor. They were the the ones in the awful places that my fingers don't ever want to go back to. Actually I used needle nose pliers to do most of the work. Funny part was they looked great, but essentially fell off, and it was the getting back on part that really sucked!! The ones on the carbs were easy to do when cleaning the carbs. It was the ones in and around the vro pump and lines leading to and from it that were difficult.

Main thing is to keep your cool and don't start trying to gorilla grip the lines. Go as easy as possible with diagonal cutters/razor knife and needle nose.

Good luck,
Winfield

 

[Faztbullet]

Re: Water squirting from between crankcase and exhaust housing

Where you are talking about is a small casting on block that looks like its made for a leverage pivot correct? Persons who dont know when removing powerhead will "pry" orj am a screwdiver in this area scoring the aluminum which will allow gaset to leak overtime.