2001 5.7L Mercruiser Engine Knock / Failure

somat84

Cadet
Joined
Aug 19, 2008
Messages
10
Hey Boater!

I have seen a lot of posts related to engine knock which has recently manifested in my 2001 290 Sea Ray Sunsport. Quick background: Engine has only 270 hours on it and receives all recommended annual service. The boat is also always stored indoors in heated storage. A week ago an engine knock started only under load at about 2000 RPM and up. The mechanic pressure checked the cylinders and noted low pressure on two. The low pressure plus hearing the nature of the knock lead him to believe the engine would require a head rebuild costing about $2k. Based on his experience and numerous forum posts he believes poor fuel as the cause of a failure. Unfortunately, upon dissassembly of the engine the issue was worse then expected. See attached pictures. I am hoping someone can help educate me on what would cause the failure in the picture. The mechanic still believes fuel may be the cause, however, my marine advertises there is no ethanol in there fuel and my starboard engine is not showing any symptoms. Also due to the extensive nature of the wear the issue has been going on for a while. I am embarrassed to say I never realized the engine was missing but am also curious why the knock symptom did not start sooner. The mechanic didn't pull the heads apart since there was no need after seeing the block. The knock could still be a secondary unrelated failure in the valves. I am more concerned with preventing failure on my starboard engine and the replacement port side engine. Any experience anyone can lend is appreciated.
 

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interalian

Commander
Joined
Jul 23, 2009
Messages
2,105
Blown head gasket quite a while ago, and block erosion between bores due to transfer of pressure between the two cylinders. You would have had poor to no compression on the two 'joined' cylinders. Knocking sounds could have been misfiring. I can't imagine why ethanol in fuel would have anything to do with it.

Saw the same thing once on a 3.0 back in my shop days. Owner had little cash so we towed the boat to a machine shop and they welded up the gap on the block. Brought it back to the shop and dressed the weld flat using a nice new file. New head gasket and the customer was back on the water.
 
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Scott Danforth

Grumpy Vintage Moderator still playing with boats
Staff member
Joined
Jul 23, 2011
Messages
50,487
fuel has nothing to do with the fire-slotting of the block. the clean and shiney cylinder had water in it. my guess the block was hydro-locked blowing out the head gasket and bending the conn-rod (hence the knock)

do you boat in salt water? could have a bad manifold
 
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