2001 Volvo Penta 5.0 GL cracked block

Scott Danforth

Grumpy Vintage Moderator still playing with boats
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Jul 23, 2011
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53,118
Being a GL, it's carb'd. I would go 6.2 liter SBC for the replacement

The VP drive won't care, and the cost between a 5.0, 5.7, and 6.2 is less than $100
 

Scott06

Fleet Admiral
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Apr 20, 2014
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7,575
Well I've watched a few videos and several boat owners had long term success with JB weld. If anyone here has tried it please add some tips.
You can try cleaning the crack and goobering it with jb, run it a few times and see if you get water in the oil. Some here have posted good results with jb on an external crack. If internal sooner or later water will fill the crank case.
if you are going to keep it as other have said get a 5.7 or 6.2 . I bought a project boat with cracked engine back in 2015, got a partial engine package from Michigan Motorz and have had over a decade of trouble free use. Was worth the money for a new engine especially compared to newer or new boat prices
 

Lou C

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Nov 10, 2002
Messages
14,346
Back then the prices were so much better than now! In fact when I did my top engine overhaul in '17, I thought then, maybe I should just get a new long block. Shoulda! Now it's like double the price from then! But I liked the challenge of re-habbing the original engine so that's what I did.
 

Scott06

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Apr 20, 2014
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7,575
Back then the prices were so much better than now! In fact when I did my top engine overhaul in '17, I thought then, maybe I should just get a new long block. Shoulda! Now it's like double the price from then! But I liked the challenge of re-habbing the original engine so that's what I did.
It’s about $2000 -2500 more now For the base engine, $3600 more for the partial engine.

Back then the difference between a reman and new base engine was not enough to bother with the reman. I think the 5.0 and 5.7 new base engines were like $3400. I pd $5 k delivered for a 5.0 partial engine/ extended base- base engine plus intake,carb, fuel pump and lines, and ignition system plus new exhaust manifolds and risers Including shipping. They gave me $150 for the old 4.3 plus mercarb and cast AL oil pan with cracked block and pd shipping back.
seemed like a lot of money at the time but between the boat, engine, and new tires and breaks for the trailer I only had $10,800 into it. Now 11 summers of use later was a no brainer.
 
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Lou C

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Nov 10, 2002
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14,346
Sure that works out to like less than a grand a year, a bargain!
I'm not sure that I would repower my old boat, it's still in good shape but it is 38 years old, with the Cobra drive system, that for me had been really good but no one but one guy around here will work on them. Lucky for me I have been able to fix the things that it needed (trim rams, water pump seal) myself. I do have a spare drive I could have rebuilt and also have a spare transom assembly as well.
Re-powering make sense because of the crazy high prices for both new and used boats, and much of what's used out there isn't in such great shape! I know this one from one end to the other....
 

Kosmofreeze

Petty Officer 3rd Class
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Aug 23, 2023
Messages
83
Lou - I can confirm that your description of what's going on with the raw water cooling on my 5.7 GXi-A is accurate. Even when I allowed the stat to open (>160F) before I poured in several gallons of the PINK AF via the muffs, most of it ended up in the risers and on the ground! When I drained the block, only a pinkish tinge. I got the desired result (i.e. undiluted PINK in the block) only by disconnecting the main/block water pump input hose at the thermostat housing and filling hose with undiluted PINK until it runs out of the open block drains - it takes less than 1/2 gallon. See attached coolant flow pic I found in my SELOC. Next year I'll do it right and save 5 gallons of AF! Thanks for the lesson.VP 5.7GXi-A Coolant Flow.png
 

Lou C

Supreme Mariner
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Nov 10, 2002
Messages
14,346
Exactly, the thermostat functions as a gate valve, and due to the fact that with an engine running at idle, it won't build enough heat in the cooling water in the block to keep the 'stat fully open, you really can't safely use the suck AF up the outdrive method with raw water cooling. Boats are designed with excess cooling capability so the excess always goes out the elbows, and the 'stat simply opens to let water that's hotter than it's opening rating out of the block.
Now if you have a closed cooling system, either a full or half system (block only) you can use the suck AF up the drive method because it is going to fill the raw water side of the heat exchanger, the raw water pump (impeller) and manifolds & elbows (if a half system) or the just the elbows (if a full system).

So I completely drain mine after fogging the carb and after making sure every drain hole actually drained, including disconnecting the bottom of the big hose on the front circulation pump, here's what I do:

replace plugs in block and exhaust manifolds, I like to put a bit of Permatex Aviation on the threads to prevent corrosion

re-connect the bottom end of the big hose for the circulation pump
disconnect the top end of that hose at the top by the 'stat housing
put a funnel in it and fill the engine with AF till it spurts out the 'stat housing neck, then re-connect the hose, now the engine is full of AF

disconnect the feed hoses for each manifold at the 'stat housing and fill each one till the AF runs out of the exhaust reliefs under the transom mount (you'll hear it draining on the ground)
reconnect those hoses, now the manifolds are full

Disconnect the hoses for the impeller (mark them first if a Volvo)
(it's a bit different with the Volvo than my OMC which has the impeller in the outdrive)
Take the hose that goes back to the transom mount, hold it down to drain, then with the outdrive down, fill that hose till the AF runs out the outdrive water intakes. This pushes water out of the hose , the PS cooler and passages in the outdrive.

With the Volvo style impeller I'd mark the hoses first and do as I just mentioned, but also, reconnect the hose that comes from the transom to the impeller, and disconnect the hose from the impeller to the 'stat housing, I would fill that hose with AF too, that way your impeller housing is full of AF and won't have a dry start in the spring.
I think this way you are 100% covered for winterizing. You can see why outboards have taken over the pleasure boat market. People got sick and tired of this rigamarole every fall. And you forget once or wait too long once and its new engine time!
 
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