Re: in-line 6 merc water in #2 cylinder 115hp
You'll need to pull the powerhead to remove the outer exhaust cover and inner plates. If this is a salt motor, use extreme caution to avoid breaking bolts as Rodbolt mentioned.<br /><br />A MAPP gas torch (relatively inexpensive from Lowe's etc) produces enough heat to help loosen up the bolts. Don't apply any more than normal force from 3/8" ratchet to get them loose or you'll snap them off.<br /><br />Worse case, drill out the bolt heads then remove the outer cover and exhaust baffle. At least then you can get vise grips on the remnants and apply heat directly.<br /><br />As for the inner cover around the ports, you'll probably have to dig out all the carbon deposits around the bolt heads before you can get a socket on them. Use a 6-point socket to avoid stripping out the bolt heads, and lots of heat.<br /><br />Recommnend replacing both the inner port cover and exhaust baffle, especially in a salt motor. If you have a fresh water motor and the covers aren't corroded badly, check them for warpage and possible re-use. Only reuse them if they look to be in real good shape.<br /><br />If the sealing surface of the block where the outer exhaust baffle is badly pitted/corroded, or the inner surface around the ports, you can have them machined. Tell the machinist to take down both areas an equal amount. Very important to maintain the correct relationship between inner and outer sealing surfaces, for example if the outer surface was machined without a corresponding amount taken off the inner surface, the exhaust baffle might bottom out on the inner cover.<br /><br />Note if you get it apart and it's obviously only the exhaust baffle leaking, you might consider leaving the inner port cover alone. Just a thought, if it's not leaking many mechanics prefer not to mess with it.<br /><br />Hopefully you've got a fresh water motor and it'll come apart easily. Out here there's mostly salt motors and we don't get the pleasure of working on fresh ones too often!!!<br /><br />HTH & G'luck........ed
