Piston head bolt rusted

[trobinson017]

Hey all,

I have a '99 Johnson 130 Oceanpro which you all have helped me maintain in great condition for the past 4 years. Thanks again!

My new problem is that during inspection of my engine I found one of the piston head bolts on the port side rusted badly. It doesn't even have flat sides anymore. All the other bolts on both sides look fine, even still have factory paint on them and all are impact-wrench tight (not by me, just an expression).

So, I know I have to replace that bolt. First, what's the best way considering that a regular wrench will not work since it no longer has flat sides? Can I just replace the bolt and resume boating or does it make sense at that point to do other things related to the head (i.e. replace gasket, check cylinders, etc.)?

I figure I have to replace this bolt ASAP so want to be sure I'm doing it correctly before I even start.

TIA as always!

 

[trobinson017]

Re: Piston head bolt rusted

I keep saying "piston head" when I probably should have said "cylinder head". I'm still learning proper boat engine nomenclature!

Also, I did a more thorough check and what I thought was the factory paint on two other bolts adjacent to the original one turned out to be rust as well. It looked like the paint was flaking a bit but once I scraped them the paint fell away and rust underneath. So the problem is worse than original reported.

Just so I can be prepared, what size bolts are these? Can a boat store look up my motor and get me the right ones?

 

[Rocky_Road]

Re: Piston head bolt rusted

Just have to ask....

I, like you, would 'cringe' to see a cylinder head bolt corroded to that point.

But...is there an issue with the running of your engine? Anything that would warrant the immediate removal of this bolt?

My experience has been...if it ain't broke...don't fix it! Too often I have created a problem, just for the sake of some cosmetic (and non-critical) thing that was bugging me.

Just curious....

 

[trobinson017]

Re: Piston head bolt rusted

Rocky,

Well, honestly, it's a kneejerk "OMG I better fix this!!" reaction. I have that inherent newbie reaction to anything rusting on my boat, the engine in particular. I just mentally see being 10 miles out in the Gulf of Mexico at the end of a fishing day, running the motor full bore back home and KAPOW! Black smoke and oil everywhere from a blown gasket. I'm sure I'm overreacting but that's why I come to you guys here, to get experienced advice to calm me down.

I'd like to hear from others on what I should do, although I truly appreciate your "don't panic" advice.

Thanks!

 

[Rocky_Road]

Re: Piston head bolt rusted

Got it...!

Consider this a 'free' bump...to the top of the New Post list.

I, too, am curious to what responses you get. They will probably range from "Ho-hum"...to "run, don't walk, to eBay and find a new short block!"

Maybe Don will jump in...(better have your serial number handy, LOL)!

Only kidding, Don...you keep all of us landlubber's britches dry!

 

[ray 6688]

Re: Piston head bolt rusted

O.K.
You will need hand tools,drill,taps,large industrial size tin of elastoplast.old
tee shirt to soak up most of the blood.
First try filing two flats on what is left of the bolt head,then try a wrench or
self grips(mole grips).
Give a few light taps on the bolt with a small hammer.at the same time trying
to turn the bolt.
Give up have a couple of beers,decide its now personal,center punch bolt
head in center and drill off head of bolt.
Remove cylinder head and try stilsons wrench on whats left of bolt,give up
go to bed,wake up next day.
Saw off bolt just above block face,drill down bolt tapping size,re tap hole.
Buy new set of stainless bolts,lightly grease threads,install new gasket.
Drink more beer,torque up head in spiral sequence.
Throw old bolts into waste bin like you really hate em.
OR
Just grease rusty bolt and leave it!
HAVE FUN
Ray

 

[NZHAWKE]

Re: Piston head bolt rusted

Hi all,

Ive had a few broken/snapped/rusted bolt issues on older Johnson/Evinrudes down here is New Zealand......having welding experience is helpful.

If you really want to sort this out now -its is always easier when there is the most above surface metal showing.......not a small rusted lump.

First and easiest is to use the biggest visegrips/locking pliers you have and attempt to lock-on and move it.

If that fails miserably- Arc or mig welding on a custom spanner nearly always gets the bolt moving. (or simply welding on a cheap 3/8 or 1/2 inch socket) This gives great moving force to a bolt/broken stud with nothing to grip. I normally use a piece of 5mm by 30mm flat mild steel bar- Bend it in a vice to suit the bolt location -allowing for the loosening movement. Snap it off when finished.You ideally drill a hole in it to allow the bolt remains to sit in- them carefully join them by a quick weld (so as to not apply too much heat). You can also just butt the end of the flat bar against the bolt remains and weld it. Make sure there is not gas/flammables around or nearby. The chance of a little fire is possible with paint and wiring nearby- keep alert! and or protect it with a thick fibreglass cloth.

All the best and take care with whatever you do.

Regards,
NZHawke.

 

[mars bar]

Re: Piston head bolt rusted

Put some go ole grease on them to stop further rusting. A couple of options... 1 drill out the bolt and use an "easy out".2 use a mig welder and weld the center of a same size nut to the back of the original bolt and remove with a socket. #1 is usually the trick but like they say 'if it anit broke don't fix it". There is enough pressure holding down the cyl head with all the bolts combined. Even with the rust there still tightly seated. good luck. -20 in ole Niagara today, no fish a biting!

 

[tx1961whaler]

Re: Piston head bolt rusted

I'd paint them leave them until you need to take the head off. You're asking for trouble, since if the bolt heads are rusted badly, you may just snap off the bolt. Then you have to take ALL of them out, maybe breaking others along the way.

 

[NZHAWKE]

Re: Piston head bolt rusted

Yep- best advise is the Whalers- If this can of worms isnt leaking - dont try fixing it.
Hawke.

 

[Woodstock60]

Re: Piston head bolt rusted

All good advice, but after many years on the brine I've learned the smartest and first thing to do is give Seatow a call and sign up. Don't lose good fishing time due to worry. Then when you have time to tackle the whole job, and do it right, attempt it. The welding ideas are the surest, but not many have access or training. If I absolutly can't get a bolt out I will try a little hand torch heat and use a cold chisle tapping the edges carefully counter clockwise. This has worked well for me on several occasions, however be prepaired to drill it out and tap. In my life anything that can go wrong- usually will. Again Seatow is the fist step.

 

[James R]

Re: Piston head bolt rusted

No biggie.
When you start having problems thats the time to pull the bolt. Untill then you should not worry. As stated if you try to rmove the so called bad bolt you may end up breaking it and have to remove the lot. When the time comes find someone with a mig welder, Meineke for example, and have a new bolt welded to the head of the bad one. The heat will help free up the old bolt and the new bolt head will help with removal.

 

[trobinson017]

Re: Piston head bolt rusted

Wow! Thank you all for the numerous and excellent replies! In the immortal words of the Beatles I'll "let it be", as many of you say I should. I'll clean up the rust a bit, paint the bolt heads and then grease them. I'll add it to my list of routine maintenance to keep them greased.

So is there anything else I should be looking at that could be a surprise "gotchya" like this one? I feel blessed to have noticed the problem today.

Thanks again everyone! yer the best!

 

[James R]

Re: Piston head bolt rusted

Using a motor in salt water means you must pay attention to flushing with fresh water every time you use it, greasing at all of the grease points, cleaning the outside of the power head and applying WD40. Removing the lower unit and greasing the drive shaft splines at least once a year. Removing the prop and greasing the prop shaft once a year. Replacing the impeller and the lower unit oil. Always use Sta-bil in your fuel.