Water in lower port side cylinder 96 Evinrude 115 v4

[trendsetter240]

Well, the fun continues. This is my freshly rebuilt E115ELED. I ran the motor last night for about 2 minutes at idle. When I pulled the plugs this morning I noticed oily water on the bottom port side plug. All other cylinders look good.

I pulled the head to check it out and found this. Any suggestions as to where the water is coming from? I'm hoping the head but is there any way to check the head / block for leaks?

 

[Grub54891]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

Are you shure that gasket surface is flat? Might just be the pic but it looks a bit rough.
Grub

 

[boobie]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

OMC did have probs back in those days with water injestion in the bottom two cylinders. They made some changes in the inner exhaust hsg to correct this. You may want to check into that.

More info. The middle wall in the exhaust U-tube was raised to be flush with the top of the adapter. Was yours like this when you had the p/h off ??

 

[trendsetter240]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

Are you shure that gasket surface is flat? Might just be the pic but it looks a bit rough.
Grub

Yeah, the surface is flat and was spotless before I installed the head. The black stuff you see is the RTV sealant I added.

 

[trendsetter240]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

OMC did have probs back in those days with water injestion in the bottom two cylinders. They made some changes in the inner exhaust hsg to correct this. You may want to check into that.

I just pulled the powerhead and found the exhaust passages in the leg are full of water. There must be a blockage somewhere. I will drop the leg and take a look now.

 

[trendsetter240]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

well I'm not entirely sure what happened here but I think the powerhead to exhaust gasket wasn't sealed properly allowing water into the exhaust ports. I'm going to thoroughly clean the surfaces and place a new gasket in there. this was a new gasket this time but maybe it wasn't a clean enough surface.

 

[boobie]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

Is the top of the exhaust tube completly flat across it ?? There should be no water in the exhaust tube when the mtr is shut off. What about winter time ?? Could you post a pic of the exhaust tube with the the p/h off ??

 

[seahorse5]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

I believe that the '95 exhaust tuner was the troublesome one

 

[boobie]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

A pic would still be nice tho' just to be sure.

 

[trendsetter240]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

Is the top of the exhaust tube completly flat across it ?? There should be no water in the exhaust tube when the mtr is shut off. What about winter time ?? Could you post a pic of the exhaust tube with the the p/h off ??

I've just put on some gasket remover to clean the surfaces. I think it was left over gasket that caused this.

I still don't know why the exhaust passages were full of water though?? When I dropped the gearcase all the water ran out. The passages are all clear and no obvious obstruction came out.

I'll post some more pics when the surfaces have been cleaned.

 

[trendsetter240]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

Here is a shot of the exhaust passage from the bottom. This passage was full to the top with water.

And here is the gearcase. This exhaust fitting was loose. Is it supposed to be sealed into the exhaust housing?

 

[trendsetter240]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

The cause of the water in the lower port cylinder was an improperly prepped gasket surface between the powerhead and exhaust. Just a stupid mistake on my part doing the assembly late at night!

I cleaned both the exhaust and powerhead gasket surfaces until they were spotless, added a new gasket, sealed it with gasket maker and installed the powerhead. The engine runs perfect now and no water in the cylinders. Ran it for 5 minutes at fast idle, pulled plugs and they were perfect.

Thanks for the help guys.

Cheers

 

[boobie]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

You have a PM.

 

[rude92bayliner]

Re: Water in lower port side cylinder 96 Evinrude 115 v4

This is the same problem that im having with my 1979 140 v4. The gasket I think your describing is the 'adapter to powerhead' gasket or maybe the models vary and your engine does not have an adapter. But, anyways. to replace this gasket i'll need to remove the powerhead.

it appears that the gasket is basically an ' 8 ' shape. the smaller hole would likely be the water passage, and the bigger one would be the exhaust?

just looking for some clarification before i start removing the powerhead

austin