I have been working on a buddies 92 Johnson 200 HP engine for a while now. It all started with simple maintenance items I was going to help him with as it sat for 2 yrs.
Well thats turned into a nightmare. It started out with just rebuilding the carbs and changing the Lower Unit Fluid, and water pump.
So I finally got all the carbs all cleaned and rebuilt, then got the Water pump changed out. The water pump was a night mare as this is a salt water boat, and it took forever to get the frozen impeller off the driveshaft. I had to cut it with a dremel. No other way around getting it off. So I got that all replaced and put the new one it.
So the first time I get the engine started, after all this work it was pumping water, but not pumping alot. So I was watching and feeling the heads, and they started to heat up, so I made the owner shut it off. I then went to pull the Thermostats out to check them, well they were corroded and all salty. So I pulled these out, and ran into some bolts breaking on us in the head on the Passenger side. So this ended up to use having to pull the head off to have the threads fixed and the broken salty rusted bolts removed. We even tried heat/pb blaster for days on this. Still no go.
Well when we pulled the head on the side we had to, we found a ton of salt/corrosion all around the heads and sleeves in the block. So I took a few days to clean up each head with cleaners and a Dremel with grinding wheel to get all the salt out of it. This was so thick there would have been hardly any chance for water to flow through there. So this was a major find.
Well we finally got a chance to start it back up after getting the heads all cleaned and fixed now, and this thing is now not pumping ANY water at all.
So now with No thermostats in the engine, and the thermostat covers sealed closed good with RTV Sealant, so no air leaks, there is no water pumping through the heads/block that I can find. I removed all the Water Hoses and sprayed water through every one of them, cleaning out all of the blockages. It is all flowing great now, but I have no water being pumped up to the engine.
So My last guess now is that something happened to the water pump impeller. So this is my next step to pull the lower again, which is no freaking fun, and check to make sure the impeller did not break for some odd reason.
I NEVER start the Engine on any boat without water flowing to the engine with the hose, even if it is just to bump the key to find something out. I always had water hooked up to it, so I have no clue unless it just failed. Only have started it 3 times total since impeller was replaced including once last night to see if it was pumping water.
So any ideas you guys might have, I NEED.
Thanks,
Bryan
Well thats turned into a nightmare. It started out with just rebuilding the carbs and changing the Lower Unit Fluid, and water pump.
So I finally got all the carbs all cleaned and rebuilt, then got the Water pump changed out. The water pump was a night mare as this is a salt water boat, and it took forever to get the frozen impeller off the driveshaft. I had to cut it with a dremel. No other way around getting it off. So I got that all replaced and put the new one it.
So the first time I get the engine started, after all this work it was pumping water, but not pumping alot. So I was watching and feeling the heads, and they started to heat up, so I made the owner shut it off. I then went to pull the Thermostats out to check them, well they were corroded and all salty. So I pulled these out, and ran into some bolts breaking on us in the head on the Passenger side. So this ended up to use having to pull the head off to have the threads fixed and the broken salty rusted bolts removed. We even tried heat/pb blaster for days on this. Still no go.
Well when we pulled the head on the side we had to, we found a ton of salt/corrosion all around the heads and sleeves in the block. So I took a few days to clean up each head with cleaners and a Dremel with grinding wheel to get all the salt out of it. This was so thick there would have been hardly any chance for water to flow through there. So this was a major find.
Well we finally got a chance to start it back up after getting the heads all cleaned and fixed now, and this thing is now not pumping ANY water at all.
So now with No thermostats in the engine, and the thermostat covers sealed closed good with RTV Sealant, so no air leaks, there is no water pumping through the heads/block that I can find. I removed all the Water Hoses and sprayed water through every one of them, cleaning out all of the blockages. It is all flowing great now, but I have no water being pumped up to the engine.
So My last guess now is that something happened to the water pump impeller. So this is my next step to pull the lower again, which is no freaking fun, and check to make sure the impeller did not break for some odd reason.
I NEVER start the Engine on any boat without water flowing to the engine with the hose, even if it is just to bump the key to find something out. I always had water hooked up to it, so I have no clue unless it just failed. Only have started it 3 times total since impeller was replaced including once last night to see if it was pumping water.
So any ideas you guys might have, I NEED.
Thanks,
Bryan