1998 Force 40 HP - water droplets on spark plugs

[Bill Ed]

I have water droplets on the spark plugs of my Force outboard motor. It is not coming from the gas tank, I have run it right out of a gas can and still get the water. The compression in both cylinders is 125 psi. I removed the cylinder head and could not see any indication of water leakage around the head gasket or any cracks. I cleaned the old gasket off the head and block and installed a new head gasket torqueing it to 225 in-lbs in the proper sequence. I installed new sparks and started the motor. It ran for maybe a minute and started misfiring and died. I removed the spark plugs and they both were wet with the lower plug wetter than the top plug although both were wet. Is there any way that water could be getting to the spark plugs besides a bad head gasket (which it not), cracked head or cracked block?

 

[pnwboat]

The gasket or baffle on the exhaust cover is a possible source for water leakage. Typically the lower plug gets wetter because water flows down. Part number 12 and 14 in the link below.

http://www.crowleymarine.com/mercury-outboard/parts/2532_9.cfm?mdl=V4ZQZ2

 

[jerryjerry05]

If you try to remove the exhaust chest cover??
Be VERY careful as the screws are weak and can twist off real easy.

I spray with PB Blaster, heat with a small propane torch, then tap the screw head with a small hammer.Repeat 2-3 times.
Then try to loosen, CAREFULLY!!!
The combo of heat, spray and tapping helps break up the corrosion that the reaction of dis-similar metal causes.
Even then you might still break a few.

 

[Bill Ed]

I plan to replace the gaskets on the exhaust chest cover. Do I need to put anything on the gaskets (like gasket sealer)? Do you know how much torque to use on the bolts? I assume that it is not too much.

Thanks for the advice on how to get the bolts out.

I will post with hopefully happy results after I get this done.

Thank you

 

[kbh121956]

I use silicone on my gaskets.
Screw or Nut Size Torque
6-32 9 in. lbs. torque
8-32 20 in. lbs. torque
10-24 30 in. lbs.
10-32 35 in. lbs.
12-24 45 in. lbs.
1/4-20 70 in. lbs.
5/16-18 160 in. lbs.
3/8-16 270 in. lbs.
Your exhaust port cover should be torqued at 70 in. lbs.

 

[jerryjerry05]

Just posted this on another post.
Maybe you can use some of it??

(Anti-seize in salt water becomes Perma-seize.​

The factory didn't use any sealers on their bolts.​

Yes do use a sealer on the gaskets.​

When the motor was new and the edges were sharp and defined, they didn't use a sealer on the gaskets.​

But you'll need to or the water leak won't go away.​

The bolts aren't anything special.​

There are 2 sizes 1/20X3/4 ​

And 1/20X 2.5 These bigger ones need to be torqued to 270 in. pounds??​

Sounds like a lot but check the manual.)​