1999 Optimax 135 - Leaking Poppet Valve through weep hole

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Author Topic:   1999 Optimax 135 - Leaking Poppet Valve through weep hole

adriano posted 03-15-2009 06:47 AM ET (US)
Hi all,
I have just completed a Rebuild of the Powerhead of a 1999 135 2.5L DFI Optimax and as part of the rebuild I also replaced the Poppet Valve Diaphragm and Grommet.
Engine is now running fine beside the fact that I have a leak from the weep hole on the Poppet Valve. I have disassembled and reassembled the Poppet Valve at least 8 times and tried several things
- Changing the direction of the water deflector
- Adjusted the spring tension by trying from fully screwed in to fairly loose
- Replace the housing gaskets
I have noticed that the inner housing is a bit corroded after having tried to clean it by soaking a few days in some CLR and blowing it clean with an air compressor. My feeling is that the housing is not contacting well with the diaphragm but I am really at a lost as nothing I have tried seems to be able to stop the water from coming out of the weep hole as soon as the RPM goes past idle.
Any ideas on what I should try?
Thanks,
Adri
aussiejake posted 03-15-2009 07:02 PM ET (US)
Hi Adri,
I should have said yesterday when I was there to try some form a gasket compound on the gasket to help seal it.

sosmerc posted 03-15-2009 08:44 PM ET (US)
Hi Adri !
What you might need to do is surface the inner and outer plates with crocus cloth on a piece of glass. And be sure to clean out all the salt buildup in the narrow groove that the edge of the diaphram sits it.
The screw needs to be secure in that water can leak past it and get on the wrong side of the diaphram.
Tohsgib posted 03-16-2009 11:35 AM ET (US)
Have you tried teflon tape?

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Author	Topic: 1999 Optimax 135 - Leaking Poppet Valve through weep hole
adriano	posted 03-15-2009 06:47 AM ET (US) Hi all, I have just completed a Rebuild of the Powerhead of a 1999 135 2.5L DFI Optimax and as part of the rebuild I also replaced the Poppet Valve Diaphragm and Grommet. Engine is now running fine beside the fact that I have a leak from the weep hole on the Poppet Valve. I have disassembled and reassembled the Poppet Valve at least 8 times and tried several things - Changing the direction of the water deflector - Adjusted the spring tension by trying from fully screwed in to fairly loose - Replace the housing gaskets I have noticed that the inner housing is a bit corroded after having tried to clean it by soaking a few days in some CLR and blowing it clean with an air compressor. My feeling is that the housing is not contacting well with the diaphragm but I am really at a lost as nothing I have tried seems to be able to stop the water from coming out of the weep hole as soon as the RPM goes past idle. Any ideas on what I should try? Thanks, Adri
aussiejake	posted 03-15-2009 07:02 PM ET (US) Hi Adri, I should have said yesterday when I was there to try some form a gasket compound on the gasket to help seal it.
sosmerc	posted 03-15-2009 08:44 PM ET (US) Hi Adri ! What you might need to do is surface the inner and outer plates with crocus cloth on a piece of glass. And be sure to clean out all the salt buildup in the narrow groove that the edge of the diaphram sits it. The screw needs to be secure in that water can leak past it and get on the wrong side of the diaphram.
Tohsgib	posted 03-16-2009 11:35 AM ET (US) Have you tried teflon tape?