Powerhead Removal.... Need some advice

[pondcare]

2003 Utopia 205. Ok... I removed all 11 nuts holding the engine to the plate. I'm now trying to lift the engine out, but it seems to be stuck. I need to replace the jet pump housing. Can this be done without the engine being removed? Any advice would be great. I don't want to break anything...

Thanks in advance!

 

[Dr Honda]

If all the nuts are off... then it will lift out. There is a gasket... but it shouldn't be holding too tight. (assuming you have the cables, hoses, and power off too)

No... you can't remove the pump with the engine in place. Basically... the pump mounts to the hull... and the engine mounts to the pump.

 

[pondcare]

I see the gasket below the adapter plate. I have everything disconnected and all 11 nuts off the plate bolts. I can't even rock the engine loose. Could it be possible the adapter plate has corroded to the powerhead? I'm totally perplexed...

 

[Dr Honda]

AAAGH!!!!!


DO NOT ROCK THE ENGINE !!!!!! The drive shaft comes out of the pump, and directly into the crankshaft of the engine. It's only about 3" long. If you rock the engine... you WILL damage something. You have to lift it straight up. AND... it's over 300 Lbs. So... you need an engine lift/hoist... and you need to use the lifting eye that threads into the flywheel.

 

[pondcare]

I may not have been clear... the problem is the engine won't lift. I already have a hoist connected the ring hook.

 

[Dr Honda]

OK... I thought you were just trying to rock it, to break it... and push it to the side. (sorry)


I would double check to make sure you got all the bolts out.

 

[pondcare]

No problem... Yeah, everything's disconnected and should just lift. When I first tried to remove it, the hoist started to lift the rear of the boat (not good) so I immediately release the hoist as not to cause any damage. I just sprayed everything around the adapter plate with PB. Unless there is more than 11 nuts that need to be remove it should be good. Does the engine or boat need to be level prior to lifting? Thanks again!

 

[Dr Honda]

I've pop'ed out 2 mercs over the years... and both just lifted out.

The reason I was saying about double checking the nuts, is because there may be a couple on the water box/expansion chamber that don't hold the pump down... but you may have counted them as the hold down bolts.

 

[pondcare]

The 6 nuts for the expansion chamber are a smaller size and I triple checked... This is driving meee NUTS!

 

[pondcare]

On Saturday, i'm gonna go over everything again just to make sure. Also, i'm gonna level the engine to make sure it pulls straight off the bolts. Hopefully, all goes well. Thanks again for your help! Much appreciated!!!

 

[Dr Honda]

Once you put a little pressure on the engine with the hoist.... Try tapping around the base with a hard mallet, or "Dead Blow" hammer. Don't use rubber, because too much energy is defected back. (as a bounce) and don't use a steel hammer. So... wood, brass, aluminum, urethane... etc.


If you are 100% on the nuts... then all that can be holding it, is some corrosion. But I remember a guy working on a boat, last season, who's pump was dang near rotten... and I don't remember him saying his engine was stuck like this.

 

[pondcare]

Perfect! I will try that... Thanks! I'm trying to get my cracked and corroded pump off. My boat was left in the water during a period of it life and every fix has been Pandora's box!

Thanks again!!!

 

[pondcare]

Got it out! What a BB... Anyway, now the pump seems to be stuck. Any good advice for that? Also, I need to replace the steering cable. Does anyone have a part # for a 2003 Utopia 205? As always, thanks!

 

[Dr Honda]

Sounds like this is a salt boat. Everything is going to be corroded. Soak it all in PB blaster... then try again.


So... was it just corrosion holding the engine down?


Cable P/N is 204390172

 

[pondcare]

Yeah, totally salted... Yes, the corrosion was holding it on. It took me about 2 hours to get it out. I had to put tension on the engine with the hoist and a lot of smacking with a 2x4. Very happy to have it out!

I have the pump soaking now. Hopefully, it will be out tomorrow. Thanks for your help!

oh... is it easy to replace the steering cable?

 

[Dr Honda]

oh... is it easy to replace the steering cable?

Baring the corrosion... It's not to bad. I had to change my reverse cable last fall. It took about 35 min. The hardest part is cutting some of the zip ties, as the cable goes up into the hull.