05 180 overhaul

[chlarson23]

Hello everybody, it's good to be back after being away from the forum for so long. I had a rather unfortunate event last summer when my Super Charger took a crap on me and deposited all the needle bearings in my engine.

I've been extremely pissed off at the situation and honestly, I just decided it would probably be best if I didn’t log onto the forum due to the fact that I couldn’t even stand to look at my boat for the longest time and I really didn’t have anything good to say. On the bright side, I have recently regained my passion for my boat and it may seem stupid to some but I have calmed down enough to work on her again. I’ve been a mechanic in the Army for going on 10 years now and if I’ve learned anything, nothing seems to go your way when you’re mad and stuff tends to get broken.

So I took a little vacation last week and finally got started. I wish now that I had taken pictures of the whole process but I’ll start from here.

It’s been a learning process to this point and I’m sure it will continue to be all the way to the end.

So, What I’ve done:
Removed
Pump
Drive shaft
Water pump housing
PTO housing
Super charger
Oil pump

I found that a lot of the stuff I’m doing has been done by someone on the forum so I’ve been lucky so far on finding tips to get it done. The drive shaft was a little tricky for the first time and the PTO Housing was just because I didn’t want to screw nothing up.

What I know is that there are 40 needle bearings on the super and I have found 15 at this point and some other metal shavings from the gears.
I am literally 2 engine mounts a fuel line and a couple of wires from the engine coming out so me and some buddies will be pulling it this weekend and I will start tearing it down and cleaning it out.

Here’s the one Pic that I have for now and I’ll start documenting my work a little better and updating the thread.

 

[BMANN06]

I feel your pain brother ... I've rebuilt 6 of these 4tecs to date, won't claim I'm an expert but if yah have any questions feel free to post em' up or shoot me a pm.

 

[fannman]

hey chlarson hold your head up buddy, im a mechanic by trade also and I am fixing to pull the superchargers on both my ski and my speedster and put the riva washers in them and check them out also for signs of unusual wear and put them back in to avoid any major mechanical problems this summer hopefully,ive done a lot of research on here on those motors and from what I can tell they should be pretty simple,,motors are motors just follow all the specs and torques keep us updated

 

[chlarson23]

I appreciate the support and wish this was going to be a quick process since it's already in the upper 90s down here, but between work and all the other stuff I got to do, i'll keep working on it and hopefully get her back on the water this summer.

 

[chlarson23]

Update

Finally after two weeks I got some more time on my boat. I was able to get the engine out and the hull cleaned out. I just used regular old dish soap and hot water to clean the oil out after I sucked the oil out. You'll see in the pictures that I was able to get her out and set her on a table in my garage.

First thing I did was take the fuel rail and the valve cover off.
Second I removed the intercooler
Third I took off the oil cooler and the exhaust manifold was last.

I was able to get it propped up and standing upright and I can honestly say that it is at this point that i am getting mildly apprehensive about what's next. I need to break her down and clean her out and I know it’s going to take time and attention to detail to make sure I do everything right.

So I am taking the weekend with my family in Florida so hopefully the following one I can get everything tore down and cleaned out, take a final inventory of parts needed and get them on order. I'm shooting for the end of July with my schedule to have her water borne again.

 

[chlarson23]

UPDATE....

I was finally able to get my engine broke down and cleaned out; here are some of the things I discovered.

One of my Oil pumps was pretty screwed up, specifically the one in the oil filler tube. There is a little screen that was slightly warped and allowed metal shavings to slip by and do some damage.

Needle bearings will go everywhere and make you work to find them. I found about 25 of the 40 in the lower half of the crank case hidden away in an oil passage that flows from the super charger side to the other. There were a couple sitting next to the oil screen by the pump and about 4 stuck to and around the stator. Grand Total was 38.5 which means there is one and a half somewhere that are unaccounted for and after several hours of strenuously searching I never did find them. I flushed out everything and cleaned it all really well so I hope they magically found their way out and I dropped them on the floor or something.

With the help of my buddy we were able to get everything back together with a new gasket set and torque to specs. I was tired of working on my plastic table so I built the wood one that it’s sitting on in the pictures; it’s about 4 foot tall and puts most of my work right at a perfect height for me. Over the last week or so I put the PTO housing, water pump, oil cooler and engines mounts on and torque them down. Going to order the oil pump and housing this week and install them following which I will begin putting the engine back in the boat, leaving only the Super. I hate working on a budget and wish I could just get what I want now but you got to do what you got to do.

And just for the record the exhaust and intercooler are on there with just a couple of bolts to get them off my work bench. I pulled the engine out with them connected and me and my buddy had to lift the awkward heavy engine out. It wasn’t till I got it out that I realized how easy they were to take off so my plan is to reinstall the engine and bolt those on last.

 

[SLOWBRAH]

I hate to hear about your outcome. I just picked up an 05 with 39 hrs (dealer verified). How many hours were on your motor before she self destructed?

Keep up the good work!!

 

[chlarson23]

The previous owner told me 20 hours which I know was a lie. I never did take it to the dealer to have it checked, it had pump issues and ceramic washers so I know it needed some attention. I hate to admit it but the failure was most likely a result of my work on the boat.

I still don't know how it happened but i rebuilt my own super, used all the right parts, tools and lubricants to do it, followed all instruction to the T, torqued everything, used loctite, and the stupid thing still blew on me. I have been pondering what happened for over a year now, and still have no idea how it happened. but oh well.

Got to go to a specialized school for my job next month so just another delay in progress, guess i'll finish her up in september.