Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

[Bikeluver43]

Good Afternoon all,

I've done a lot of reading these past few days and know what is required in regards to procedure. Before I start here is the backround:

1994 Sea Ray 180 Islander Bow Rider, 3.0 Merc I/O (sorry no tag #'s as I'm at work). Same story as most every other post - purchased from an older gentlemen, said it was drained prior to last winter and he didn't use the boat at all this season. I got it for a good deal after selling my other boat - 14' Sportcraft 70HP Evinrude.

Come home, start it up and see water coming from the flywheel area- this was not there while running at his house on muffs. I've inspected the motor -sides, as far down and up as I can see thus far and no cracks. Oil also is nice and clean/not overful. I'm praying its simply a freeze plug but know it could be more.

So with my research I've found the engine needs to come out - which from what I've read online and seen in the service manual - seems relatively simple. My questions are this -
When removing the outdrive, is there a gasket that needs to be replaced?
Is it simply the outdrive unit that comes out when the 6 bolts are removed or do you need to go all the way to the transom mount?
Do you need to align the motor again if you unbolt the mounts from the stringers and don't mess with the adjustments?
Is there any other gaskets or parts required when removing a motor like this?

I appreciate the help in advance.

 

[alldodge]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

(1) When removing the outdrive, is there a gasket that needs to be replaced?

(2) Is it simply the outdrive unit that comes out when the 6 bolts are removed or do you need to go all the way to the transom mount?

(3) Do you need to align the motor again if you unbolt the mounts from the stringers and don't mess with the adjustments?

(4) Is there any other gaskets or parts required when removing a motor like this?

(1) Yes and it is recommended, while doing so to also replace the impeller and see if water pump housing needs replacing. Your service manual will identify the gasket. Also check bellows and gimble bearing

(2) Yes just the 6 bolts, transom does not need to be removed. Place shifter in full forward gear, remove spedo tube from between drive, and remove hydraulic trim cylinders.

(3) Yes, and for the recommended to check alignment every time drive is removed, and every time engine is moved. Real cheap insurance

(4) No, not to just remove ana reinstall

 

[littlebookworm]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Before you pull the motor, I suggest you double check that its a freeze-out plug problem. Get one of those mirrors on a wand (try HarborFreight Tools) and a flashlight or trouble light to look behand the engine. You might have to remove the exhaust pipe to look in there, but that would have to be removed anyway to pull the engine. There is a hose and a thru-transom fitting back there, either of which could be the source of your leak. Unfortunately, you'd probably have to pull the engine anyway to replace either of those, but it's worth a check first. Hy

 

[Bikeluver43]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

I'm just about positive its the core plug, the water comes out by the starter. Definitely in the flywheel area.

Anyone know the size of the plug back there?

 

[Bikeluver43]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Oh yeah this leak was found while on the trailer hooked to muffs at my house.

 

[Bondo]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Oh yeah this leak was found while on the trailer hooked to muffs at my house.

Ayuh,.... AllDodge has got yer answers,... The gasket set is 'bout $7.00 for the outdrive,...

 

[achris]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

There are videos you might find helpful up in the 'stickies' area....

Here is the link to the videos....

http://forums.iboats.com/mercruiser-i-o-inboard-engines-outdrives/couple-new-videos-590378.html

 

[NHGuy]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Take a good light and look down at the fitting where the cooling water enters the boat. It's just above the exhaust on an Alpha 1. But your Gen 2 may be different. If it is someone will update me. It should be a hose barb with a piece of hose that's around 3/4" inside diameter. If there is a split or a hose off there it could be your issue.
If that's not it I'd recommend pressure testing your cooling system. That's done before removing the engine. Get some line clamps to block off the outgoing water to the exhaust. Pressurize the system via the water input. I block the incoming water line with a tire valve in a plug, into which I put 15 psi of air. Then watch and listen to make sure you are fixing the right thing.

 

[Scott Danforth]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

if a core plug is pushed out, accept that the block may be junk and hope for the best. They are not, and never will be expansion/freeze plugs. they are plugs to remove the core sand from the casting process period.

that being stated, look first with a mirror. could be a simple bad hose.

 

[Bikeluver43]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

(1) Yes and it is recommended, while doing so to also replace the impeller and see if water pump housing needs replacing. Your service manual will identify the gasket. Also check bellows and gimble bearing

(2) Yes just the 6 bolts, transom does not need to be removed. Place shifter in full forward gear, remove spedo tube from between drive, and remove hydraulic trim cylinders.

(3) Yes, and for the recommended to check alignment every time drive is removed, and every time engine is moved. Real cheap insurance

(4) No, not to just remove ana reinstall

Great I appreciate it. I was hoping that would be all that was needed. I'm going to order the gasket and alignment tool and hopefully get this done in the next few weeks.

In regards to the bellows - if they are in need of replacing, are they serviceable without removing more of the outdrive?

if a core plug is pushed out, accept that the block may be junk and hope for the best. They are not, and never will be expansion/freeze plugs. they are plugs to remove the core sand from the casting process period.

that being stated, look first with a mirror. could be a simple bad hose.

And I accept that - tried to make it clear in my first post that I'm hoping its not more but certainly could be. I understand they are not "freeze plugs or expansion plugs" even though most call them that. If the block is cracked, its an exterior crack and I'll do the JB Weld route and run it while I keep an eye out for a good used motor. The price of the boat was very inexpensive for its overall condition that I don't mind spending a little more to get it to top notch shape.

As for the hose, I will definitely check back there but from what I could see (standing by the throttle since I shut it off pretty quick at the site of water) it was pushing water out by the starter, between the bellhousing. It would only come out with the engine spinning - turning to start or running.

 

[Shelby Ladner]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

There is a plug on the rear of the 3.0 that is hidden within the bellhousing. You will have to remove the engine and then remove bellhousing to access it. Water leaked from mine just as you described-around the starter. Be sure to apply sealant to new plug when you replace it. The 3.0's usually freeze crack in the middle, port side, of the block directly under the carb.

 

[Fishermark]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Here's what you are likely to see once you pull everything. When you replace the core plug, make sure you use brass - not steel.

 

[Bikeluver43]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Thank you for the picture, it certainly makes it easier to find what I'm looking for.

Does anyone know the size I need to get for the plug? Just want to have it ready for when I pull the motor.

 

[achris]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Should be 2" (according to my parts catalog)...

 

[Bikeluver43]

Re: Removing Engine to Replace Core/Expansion/Freeze Plug - Need Info Please

Thank you achris!