2004 Mercruiser Chaparral . . . it happened . . . engine work ahead

gergAlicious

Seaman
Joined
Jun 25, 2011
Messages
53
So my job took a turn for the better late in 2016 and I was home pretty much on weekends only long enough to sleep and recharge. Needless to say everything was neglected, even the NEW drain plugs I put in for winterizing the engine the year before. So . . . . exhaust manifolds and at least one head cracked in a freeze. Yep, absolute bonehead move. But I am ready to fix it.

I had actually got it running for the first time of the season last July, and as I was ready to walk away and let it run in the driveway for a while, I decided to look under the cover and saw water gushing out of the port side. Thinking it was the manifold only, I removed that side and right away I could see the head had cracked / expanded also. :(

I was going to just put a long block in it. But here is the simple ask for you experts. I am going to start on it today, removing everything I need to so I can basically bear hug the engine (maybe not literally) - if I get the intake / heads off, can I do a decent enough inspection in the valley pan area and outside (where I presume there are CORE plugs?) to determine if the short block is OK? I would much rather put a set of heads on it and a new exhaust setup than pull the whole thing if I do not have to.

There was NO water in the oil I will also add. Engine ran VERY well also. This is a very low hour engine, which makes me that much more sick to my stomach about the whole ordeal. I am the third owner of the boat I believe.

If I can inspect it good enough and repair this way (presuming I find no visual cracks) I can work on it here at the house. If not, it becomes a much larger task - getting to my shop and then configuring a chain hoist to get it lifted out.

All comments / thoughts and guidance will be MUCH appreciated!
 
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