Thermostat Replacement 140 johnson

Hennysemitara

Petty Officer 2nd Class
Joined
Aug 4, 2016
Messages
175
So my outboard overheated a month ago, and i ran compression 120 across the board. I think i may have melted the thermostats. Is doing this job pretty much straight forward? 3 bolts on the thermostat housing remove and replace? Any tips or suggestion?? Aloha!!
 

mjf55

Chief Petty Officer
Joined
Jun 17, 2014
Messages
462
Be gentle and patient. You may have corrosion on the bolts making it difficult to remove. Use PB plaster. Use heat if needed. Go slow.
 

interalian

Commander
Joined
Jul 23, 2009
Messages
2,105
Working under the bubble exhaust is a pain. You'll need to remove the plastic shroud under the bottom motor pan, then remove the two rear bolts that hold the pan to the exhaust housing. After that's loose, pry the pan downward to give you some space and brace it there with a couple of scraps of wood (Koa is best).

The screws may be frozen, so use patience for extraction. Once they're all out, be prepared for a small explosion of springs and poppets once the gaskets separate.

Make sure the two little holes in the plastic spacer plate are clear - if blocked, you'll air-lock the cooling system and it'll overheat. Some say enlarge these slightly to reduce the chance of blockage (I did but found it ran too cool as a result - YMMV).

Re-assembly is reverse, but I find it easiest to glue up the casting to the spacer using a new gasket and clamp it in a vice to cure. Then glue the poppet springs to the poppets, and the thermostats to the spacer. 3M 847 is my glue of choice. Then tie the poppets to the assembly with thin zip ties to permit finagling the assembly i place with a minimum of cussing. Once you get the bolts started, cut the zip ties then tighten the bolts evenly.
 

Hennysemitara

Petty Officer 2nd Class
Joined
Aug 4, 2016
Messages
175
Working under the bubble exhaust is a pain. You'll need to remove the plastic shroud under the bottom motor pan, then remove the two rear bolts that hold the pan to the exhaust housing. After that's loose, pry the pan downward to give you some space and brace it there with a couple of scraps of wood (Koa is best).

The screws may be frozen, so use patience for extraction. Once they're all out, be prepared for a small explosion of springs and poppets once the gaskets separate.

Make sure the two little holes in the plastic spacer plate are clear - if blocked, you'll air-lock the cooling system and it'll overheat. Some say enlarge these slightly to reduce the chance of blockage (I did but found it ran too cool as a result - YMMV).

Re-assembly is reverse, but I find it easiest to glue up the casting to the spacer using a new gasket and clamp it in a vice to cure. Then glue the poppet springs to the poppets, and the thermostats to the spacer. 3M 847 is my glue of choice. Then tie the poppets to the assembly with thin zip ties to permit finagling the assembly i place with a minimum of cussing. Once you get the bolts started, cut the zip ties then tighten the bolts evenly.

thanks for the tip, i will try to be patient. i will be sure all holes are clear. btw its funny that you mentioned koa. my dad works on wood and i use his koa as spacers and stuff.
 

interalian

Commander
Joined
Jul 23, 2009
Messages
2,105
thanks for the tip, i will try to be patient. i will be sure all holes are clear. btw its funny that you mentioned koa. my dad works on wood and i use his koa as spacers and stuff.

I'm only kidding about the Koa - any wood will do. I get a vibe you're from Hawaii and am super jealous of your location. We were "Maui'd" near Lahaina in 2012 and have been to the islands about 9 times in the last 6 years. Now, back to regular programming.
 

Hennysemitara

Petty Officer 2nd Class
Joined
Aug 4, 2016
Messages
175
So i tried to use wood to wedge the engine base cover down so that i could access the bolts, it did not budge. gonna drill holes and fill with gromets.
 

interalian

Commander
Joined
Jul 23, 2009
Messages
2,105
That'll give you access with a socket and extension. Good choice. Without gaining some space it'll be fun getting the housing off and back on. Get your cuss jar change ready.
 

Hennysemitara

Petty Officer 2nd Class
Joined
Aug 4, 2016
Messages
175
No Title

okay so i got the thermostat housing off i drilled the lower engine cover 2 holes this is how it looks,,,
 

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Hennysemitara

Petty Officer 2nd Class
Joined
Aug 4, 2016
Messages
175
now i can replace my thermostat easily some people take the powerhead off just to do that thats crazy,,,
 

interalian

Commander
Joined
Jul 23, 2009
Messages
2,105
Pretty crusty. And you can see the thermostats are stuck open, one much more than the other. Get a complete kit with new poppets, rubber rings, t-stats and springs. Fun part is putting it back together.
 

Hennysemitara

Petty Officer 2nd Class
Joined
Aug 4, 2016
Messages
175
yea i think ill be okay putting it back in hopefully.cleaning up the parts today gonna put it in tommarow
 
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