1989 Crusader 454 problems. Need help.

Sorry about the looooong explanation but I need some serious advice. My boat is at a local shipyard and they’re telling me I’m due for a repower on my boat. This is the last thing I was expecting before I took it there. I bought the one year ago. It was in the great lakes (freshwater) and both engines had less than 1000 hours. The boat hadn’t been used in 7 years and was on the hard. The first time I started the boat there was antifreeze that came out of the exhaust so I’m pretty sure it was properly winterized. Also, when I purchased the boat the compression test for both engines was around 140 lbs. After purchasing I brought the boat to the Carolinas.

Earlier in the summer my 1989 Crusader 454 (starboard side) started to overheat only over 2200 RPMS. Everything below 2200 RPM the engine was fine. After this started to occur, I used the engine for another 15 hours or so. During that time period I never went over 2200 RPM because of the overheating issue.

I took the boat to a local marine mechanic and they started chasing the overheating problem. First they replaced the manifolds and risers. Every time the boat was started you could see rust in come out of the exhaust so I figured it wasn’t a bad idea. That didn’t fix the overheating problem so they pressurized the heat exchanger to learn that it wouldn’t hold pressure. So the heat exchanger went off to a shop and they fixed a couple of pin holes. After the heat exchanger could hold enough pressure they reinstalled it and the engine still overheated. Next, a couple of hoses and the impellor were replaced. Another sea trial was performed to find out it still overheated. After that didn’t fix it they replaced the cooling pump. Still overheating. Next they told me that they sea trialed the boat and the cooling system will stay pressurized until it hit 2200 RPM and then it would start to lose pressure. They also said they did a compression test on both engines and they are around 40 lbs each.

So now their recommendation is to repower the boat because there is most likely a crack in the block and there is coolant leaking into the heads. Ugh! I had noticed steam coming from the exhaust just around or before the overheating problem.

I’m not sure what the answer is. Could it be something else? Should I take it to a second mechanic and get a second opinion on what the problem could be and possible solutions. I don’t want to pay for a repower. Who does!?!? I don’t know if this boatyard is the best to deal with considering it look them replacing almost the entire cooling system up to this point and now recommend a repower.

Thanks so much for helping me so far. It’s been great to hear everyone’s opinion since I have not been in this situation.

I stopped in yesterday to talk to them and ask a few questions that you recommended. The compression test results they wrote down for both engines were from the low 50’s to high 60’s per cylinder. Even though the starboard engine is the only one overheating, they tested both to compare the results from on to the other. One year ago the compression test results were all in the 130’s to 140’s range per cylinder and at that time, a year ago, the boat had not been run in years, so I was told. Does anyone else know why and how or if it’s possible for the compression to drop almost 100 psi over the last year?

The engines were running fine with the exception of the starboard overheating. Would they run that well if the compression was only in the 50’s to 60’s range?

I checked the oil and there is no coolant that is leaking into the oil. There is a lot of vapor coming from the starboard exhaust. I have identified that there is not a pressure leak in the coolant cap. I also don’t know if there is a cracked head since they have not pulled that part of the motor apart yet. Also, all of the plugs looked okay.

Their recommendation is to buy a remanufactured block because the cost of labor to machine the head which may or may not fix the issue would be almost as much as buying a remanufactured long block.

The estimate is $7,500 to pull ONE block and reinstall a remanufactured long block. They recommended doing the same to the other engine because of the low compression results. The notes from the estimate included:

Remove engine. Remove heat exchanger, exhaust risers, coupler, transmission cooler, alternator and carburetor before lifting engine. Transfer parts from old engine to long block. Install and align engine.. Spark plugs, coil, wires, dist cap and rotor, oil etc Hose, clamps, coolant etc. ASSUMPTION: Engine and trans mounts are re-usable. NOTE: Suggest getting the starter and alternators reworked. NOTE: May want to replace the oil/trans cooler.

I asked if it was a bad head gasket and he said its a bad head or possibly a cracked block and they’re not sure.


Any thoughts that would help?

I dont know why it would be at 40 and that's why I think something is fishy. Yes, there is only a problem with one engine. I'm not familiar with exhaust back pressure. What are your thoughts?

The boat starboard engine would start to overheat around 2200 RPM. The port doesnt overheat.

They have no idea if it is cracked which is fishy to me. You would think they could determine this.

For a remanufactured block and transfering old part to the reman block it will costs around 7k for the whole job.

The compression test indicated psi from the 50's to the 60's. I fault the mechanic for using a dart throwing approach to chasing the issue without a methodical diagnosis approach. The conversations they had with me was that "x" will fix the problem and then guess what... it didnt. Eventually I realized I wasnt getting expert advice. When I bought the boat, I replaced impellers and hoses along with other items.

I have considered the fuel injectors and electronic ignition. How much did it improve you power and fuel efficiency? Also, how do you know what props to go with to increase performance?

Thanks a lot for the help.

Hopefully we can figure this out!