Evinrude V4 Block, Can This Be Repaired?

L

landlord

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Joined
Jun 4, 2008
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2
Chip cylinder.jpg

Gap.jpg

starboard.jpg

1990 Evinrude 90 HP model VE90TLES

Can the chip be repaired? A local welding shop thought that they could fill the chip with a tig weld and then I would have to have the block deck milled flat again. Has anybody tried a similar repair?

On the other cylinder pictured Is the gap between the steel cylinder sleve and the aluminum block material an issue? Is there a fix for this?

Should I try to save this block or find a donor block?

Thanks in advance for any advice.
 
a70eliminator

a70eliminator

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Sep 9, 2007
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3,762
Re: Evinrude V4 Block, Can This Be Repaired?

JB weld and some finesse with a file, there's no great loads imposed on that area being the sleeve looks like it will contact the gasket, where the sleeve looses contact (gap) there will be less heat disipation but wheather it's enough to really matter is beyond me, all you have to loose is the cost of a head gasket.
 
J

jonesg

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Feb 22, 2008
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7,198
Re: Evinrude V4 Block, Can This Be Repaired?

I think the chip can be fixed, the other cyl might be out of round, it needs a marine machine shop to measure and assess.
 
H

HybridMX6

Senior Chief Petty Officer
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Oct 22, 2008
Messages
676
Re: Evinrude V4 Block, Can This Be Repaired?

Agree with both assessments above. I'd have machine shop fix the chip, and an outboard machine shop (not an auto machine shop) check out that cylinder with the gap.
I'm not an expert on these, but looks like you need to replace the water deflectors as well. Not sure if some are missing or if you removed them to inspect. Just a note.
 
E

ezeke

Supreme Mariner
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Sep 19, 2003
Messages
12,532
Re: Evinrude V4 Block, Can This Be Repaired?

Agree that the tig weld should work. The water deflector on cylinder 1 is blocking the water passage. You should replace all 4.
 
L

landlord

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Re: Evinrude V4 Block, Can This Be Repaired?

Thanks for the responses, I'll go with the suggestions and get it put back together.
 
T

TLL

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Mar 4, 2004
Messages
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Re: Evinrude V4 Block, Can This Be Repaired?

Ok, this motor has had a major overheat, the cylinders are scored and out of round so bad that it will need a .030 bore job. The top cylinder got so hot that the aluminum pushed away from the sleeve, leaving a gap. The sleeve is in fact now slightly "loose" in the block. Doubtfull if a head gasket will stay sealed long in that area. Yes you could JB weld the chip on the lower and make it work for a while, but really I think it's time for a new block. How about all the overheated blue bearings on the crank that you haven't even seen yet?
 
Chinewalker

Chinewalker

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Aug 19, 2001
Messages
8,902
Re: Evinrude V4 Block, Can This Be Repaired?

Replace the block. The area where the sleeve is separated from the block will "float". By that, I mean that the sleeve will not stay in round. Adding JB weld behind it won't help, as it will expand/contract at a different rate from the aluminum. You'll get blow-by, stuck rings and be right back where you started. I'd find another block...
 
M

mikesea

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Oct 1, 2006
Messages
1,830
Re: Evinrude V4 Block, Can This Be Repaired?

a replacement block is the way to go.HOWEVER,you can resleeve it with flanged sleeves which give a new mating surface for the head gasket.BUT,its costly.I do not wish to question anyone.I worked in 2 rebuild shops and we did hundreds. if not thousands of rebuilds .The JB weld repair in those areas sooner or later fail.If they fail at the wrong time,it can be dangerous for the user.On a lake where you can see shore.OK.But fishing the gulfstream in South Fl.you dont want to breakdown.The epoxy does seperate ,could be heat,or the further breakdown of the material it is applied to.Many believe the steel ring on the sleeve is enough for a good seal.I have witnessed not to be.Flanged sleeves are about $125 a piece and the machine work gets costly,but sometimes it is the answer.I your case many good used blocks are available,even new may be a good deal these days.A used block may need boring as well.You must also look at the ports down in the bore.They often crack between the ports,that leaves a "catch"for your rings and snags them ,that means blow up.Shopping used,look at the ports,ALL tapped holes,look for any thread repairs with heli coils.They are threaded inserts that on head bolts I dont like.They can hold,or they can strip,especially the outer holes.Look for the seperation you have in the 1 cylinder,look for welding.The best way to buy one is from a outboard machine/rebuild shop .Buy a ready to build block.That way the seller sells you a block that has all the problems removed.Of course ,inspect before you build.A good choice for you ,if the rest of the engine is clean making it a good eng for a new rebuilt powerhead.IBOATS has manufacturers that do that work.Go under the Iboat store and look for the rebuilders.They have a selection box for your state.You can buy the rebuild,ready to mount,you will reuse your electrics,carbs,all wiring flywheel ,heads,etc.I see your eng got hot.WHY,you need to figure it out ,impeller?change it anyway,rebuild carbs,.Good luck to you.Keep in touch with progress or ???'s
 
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