Johnson 150 Defective Block Casting

[jjdiv]

I understand that the Johnson 150hp, 1991-1996 had problems with the block casting leaking due to a defective lost foam casting process.

Can anyone help me with more information about this?

Did it effect all years and models?

Can you tell by serial No. if this is a problem?

Other diagnostics?

Thank you.

 

[JUSTINTIME]

Re: Johnson 150 Defective Block Casting

yep all about the serial number
any BRP dealer should be able to help

 

[Dhadley]

Re: Johnson 150 Defective Block Casting

It's what they call the "glue seam leak". Kinda hard to explain but basically two pieces of foam were put together edge to edge rather than end to end. Once the casting was done there's a rather thin line where the foam was. It did not affect all 150/175 60* blocks. It really didn't show up in many 91 blocks. The later blocks with the casting number in the starboard side were ones not affected at all.

You could have a block that ran for years without being affected. Then the leak could pop up. Many times right after an overheating incident.

It can be fixed but it requires taking the #1 sleeve out and welding. Not too big a deal if you have to deal with it. I have a 1992 and a 1993 150 and neither one does it. If you're looking to buy a 60* V6 and there's no water in #1, I wouldn't worry about it.

 

[jjdiv]

Re: Johnson 150 Defective Block Casting

Thanks Gentlmen,

Can you tell me how to evaluate for water in No. 1?

Is the casting number easy to see or is it accessable only when it is torn down?

Can you tell from the engine serial no.--I'm looking at a 93.

Anything else to be particularly concerned about?

Thanks again.

 

[Dhadley]

Re: Johnson 150 Defective Block Casting

It did happen to some 93's but if it hasen't happen to that one now, I wouldn't worry about it. If it gets water in #1, it won't run long so if this one is running, it should be fine.

Just make darn sure it has Champion plugs in it. If it has something else - beware.