New motor,now cover won't close

[kellydee]

I have a 1996 Bayliner Cierre express 2452.I just replaced the original motor (96 5.7)with a 2007 5.7 .I added the closed cooling system from San Juan Engineering.The heat exchanger sits basicly in the same spot on the top front of the motor as the old one but ,now my motor cover won't close.It hits the exchanger.I even went so far as to cut off the bottom of the new brackets (exchanger support)3/4" and re-drill the mounting holes so as to drop the assembly 3/4".It still hits.Anybody experienced this?All I can figure is the new motor(serpentine belt)is designed a little differently in the front so that the sopports are a little farther forward.Maybe 1/2".I'm gonna call the engineering co. tomorrow.The only other option I can think of is having my cover re-fabbed.THAT SUCKS!

 

[Don S]

Re: New motor,now cover won't close

I've had engine covers remade MANY, MANY times. Lots of things are different on the newer engines, manifolds and carbs are taller, engines are longer, wider, and harder to work on.
Might want to try changing that raw water pump impeller. It's a LOOOOOOOOOOOOONG way from being easy, or even possible without pulling the engine..... That cool fuel setup by the port motor mount will be another joy.

 

[kellydee]

Re: New motor,now cover won't close

Thanks Don ,thats what I'll do.No seawater pump though,Alpha 1gen 2.Now I wish I hadn't let my buddy talk me into chopping up the brand new mounts from the cc system.Oh well,done now and no real harm done.I've just gotta re-configure 1 hose.I didn't think it was normal to have the cover redone.Gonna get on that 1st thing this am and hopefully can get it back soon.Still have other stuff to do anyways but not that much.

 

[kellydee]

Re: New motor,now cover won't close

Well,here it is.To cut out the part with the blue tape on it and move it forward 2 inches,got 2 estimates today.! for $800-900,1 for $700-800.OUCH!!Hope I get a kiss with that cuz I dont have alota options.If I go with it(which I am),I can get it all going back together now and just be waiting on the cover.Hopefully,water-test and break-in by next weekend.

 

[kellydee]

Re: New motor,now cover won't close

Well,here it is.To cut out the part with the blue tape on it and move it forward 2 inches,got 2 estimates today.! for $800-900,1 for $700-800.OUCH!!Hope I get a kiss with that cuz I dont have alota options.If I go with it(which I am),I can get it all going back together now and just be waiting on the cover.Hopefully,water-test and break-in by next weekend.

Woops,forgot the pic.Here it is

 

[Bondo]

Re: New motor,now cover won't close

With alittle Fiberglass,+ Epoxy you can do it Yourself........

The required Knowledge is over in the Restoration Forum...........

For Well Under 1/2 your estimates............