Johnson 90 Ocean Runner - full 60 degree V4 powerhead rebuild

Slideshow of my 1996 Johnson 90 Ocean Runner V4 rebuild. Bought it in 2012 for $400 in a very sorry state and put it in storage.
This year I bought 17ft cuddy boat that could use an engine so rebuilt this one.
All parts delivery time: about two months
Block drilling and honning to + 0.030: two days
Assembly time: one weekend
Fine tuning, installing and misc: two days
Replaced parts:
- One head
- All bearings
- pistons
- rods
- all seals
- Crankshaft laser welded and ground back to dimension
I hate music in presentations, so no music.
Enjoy.

[@vadimus2007]

Damn, it idles sooo smooth!

[@peterjohnsson8247]

Thank you for sharing!! I'm working on an Ocean Pro 90 HP from -96, got stuck on lifting of the powerhead. The power head front is stuck and I suspect that the stearing arm is holding it. Do you have to loosen the stearing arm to lift the power head?

[@vasiliskatzalis5375]

Good job i have the same motor & i love it. Only broblem fuel consumption

[@Vore667]

Vasilis Katzalis In the meantime I bought Tohatsu 90 tldi with trashed gearbox, rebuilt it and put it on the boat. I'll report back how much difference there is fuel and power wise.

[@stevest205]

@@Vore667 Can you please tell the difference in fuel consumption?

[@Vore667]

@@stevest205 Yeah, consumption... at idle, difference is massive. TLDI 0.4L/h Johnson 5L/h. Travel speed avbout 22 knots, difference is much smaller, I'd say about 20, 25% in favor of TLDI. I now have 4 stroke yamaha 100detl and it's economic but I think TLDI burned less fuel than Yamaha.

[@aarontrenton1730]

What was your final cost in parts?

[@Vore667]

@@aarontrenton1730 give or take $1k

[@omcbob37]

At the 3:15 mark in the video, what are the 2 different types/brands of sealer you used on the crankcase?

[@Vore667]

Blue is marker for visualising the cover mating surface, orange is flange sealant - Loctite 574.

[@jamespaul1102]

Cast Pistons are more likely to blow than forged pistons. Thats what my bro got for his 140

[@heliplt63]

Nice video , Where did to find the parts for the rebuild . I was planning on doing mine after January 1st 2019

[@sickandtwisted149]

All parts are still available trough BRP/Evinrude. Etec 115 uses this exact block with few minor casting updates to accomodate dfi injection.

[@heliplt63]

@@sickandtwisted149 Thanks :)

[@brandon_j_usa4141]

What did the rebuild cost you in parts only?

[@Vore667]

Brandon Jones i didn't put all the bills together but roughly $700 for parts only and $400 for machine work & laser welding.