Cracked Cyl Jug on787

[c-D00]

Ok so starting on my 97 project challenger 1800. Temps yesterday finally rose to where I could crank the engines on the hose for the first time since I acquired the boat a few weeks ago. Engines fired right up, throttle response was good.... however I looked in the engine compartment and the aft most cylinder head had a nice stream of water coming from it. Upon further inspection it appears that there is an external crack in the cylinder jug (see pic). I am new to troubleshooting and working on engines and am in hopes you guys can help give me some pointers on the questions I have:

1. Because the engine ran and had good response, is it safe to assume that the sleeve is not damaged and only the exterior of the jug is cracked?
2. If not, what do I need to do to preserve the engine if water did get into the engine?
3. To rebuild a top end, do I need to get matched pistons and jugs or can I just buy another jug off ebay?
4. Is it advisible/possible to do this top end with the engine still in the boat or do I need to build a jack stand and pull it out?

Thanks for the help!!!
Scott

 

[Dr Honda]

That’s what happens when they aren’t winterized, and the water in the engine freezes. Fortunate for you… it’s probably superficial.

The proper way to fix it is to remove the jug, squeeze the crack together, and weld it. If you don’t want to do that… scrape it clean, and fill the crack with JB Weld or Marintex resin.

 

[c-D00]

That is really good news. I will probably pull it so that I can get more acquainted with my new boat

Thanks for the info Dr Honda. It is greatly appreciated.

 

[c-D00]

One other question for those of you that are familiar with the 1800s. Is it possible/advisible to change the cyl head/jug without removing the engine from the boat?

 

[dsw222]

One other question for those of you that are familiar with the 1800s. Is it possible/advisible to change the cyl head/jug without removing the engine from the boat?

Yes... i installed an SBT top end on my 1800 without removing the engine at all

 

[parrothd]

Ugh...Memories of the back pain......Have fun..

 

[c-D00]

Ha... yeah I am not looking forward to it. Thanks for the info guys.

 

[c-D00]

one more question

I have one more question. After further inspection i found a second crack in a spot that was not easily accessable from the outside. So, I decided to roll up the sleeves and remove the head (completly new to me) and try to perform a repair from the inside of the jug. I figured worst case is that the fix would not work and I end up having to buy a jug anyway. Everything came off easy. However, in reassembly, I see no where in the manual where it indicates I need to use new gaskets. The gaskets around each jug look good. What are your all's experiences with this... should I bolt it back up and test compression or do I just need to go ahead and order new gaskets? I made the repair using jbweld. Attached are a few pics for anyone that has an interest.

 

[BMANN06]

Looks to me like it'll work ...

If it doesn't or leaks a bit. Let me know, I've got 4 jugs that are in great shape laying around up here. They had really good compression just lost the crank. You'd prolly be able to know if it'll work running on the hosea and trailer, keep me posted and we can work a deal out (don't really think i need four of em').

Bri

 

[Dr Honda]

I wouldn't have put the JB weld on the inside of the jugs. If it cracks loose (and it will from expanding and contracting)... it can plug up the smaller water ports, and cause the engine to overheat. JB weld is an external patch.

I would remove the jugs, and have them fixed correctly.

If you do remove the jugs... look at your base gasket, and see how many punch marks are in it. That will tell you how thick it was, and you can replace it with the right one.

 

[c-D00]

Bri, thanks for the offer..... based on Tony's feedback, I may be taking you up on your offer.

Tony,

Thanks for the feedback and you make a very good point. Was thinking I was being really innovative . Oh well... That will teach me. lol. Okay so I may be back at square one.

 

[Dennis]

Your cylinders are cracked because water in the jacket froze. That water should have drained ... it didn't. There is a drain hose at the base of the cylinders that is clogged. You better check the other engine drain also.
GOOD LUCK!

 

[BMANN06]

Bri, thanks for the offer..... based on Tony's feedback, I may be taking you up on your offer.

Tony,

Thanks for the feedback and you make a very good point. Was thinking I was being really innovative . Oh well.
.. That will teach me. lol. Okay so I may be back at square one.

No prob. Have a look around yah may find one locally (eBay kijijji etc). If not shoot me your zip and ill get a shippin cost.