Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

[tkrfxr]

I just found some bleeding rust at the joint between the exhaust manifold and the elbow risers, in the port engine...(STBD engine looks ok)

The boat is 6 seasons old, salt water 6-months of the year.

Twin Volvo Penta 5.7 OSXi-DF (factory-installed closed cooling).

Any suggestions? Should I separate the risers?

 

[Bondo]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Any suggestions? Should I separate the risers?

Ayuh,... You can start there,...
Replacing the Whole Shebang is where you'll end up though....

You're Overdue...

Are the manifolds raw water, or on the fresh side,..??

 

[Don S]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Time to pull the risers, inspect the gasket surface to make sure it hasn't shrunk in size in the web between the water and exhaust port. If it's still good, put on the new style OEM gaskets and go boating. If that web has thinned down or become carbon and not metal, replace the manifolds and risers.
Closed cooling has nothing to do with the manifolds and risers on Volvo engines.

 

[tkrfxr]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Ayuh,... You can start there,...
Replacing the Whole Shebang is where you'll end up though....

You're Overdue...

Are the manifolds raw water, or on the fresh side,..??

How overdue? Is there a time interval in which the manifolds are due for change, or is it wear (or rust) related?

The manifolds exhaust the saltwater...hence the rust...

Thanks, and I'll post a picture of the joint surfaces to get your opinion on it...

 

[Don S]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

There is no exact time, but when you start seeing rust tracking on the outside, you can bet money it's time to check the inside also.
After 5 years in salt, it's not a bad idea to pull the risers anually during winterization or anually at some point if you live where it doesn't get cold, and look at the wear on the passages. It will be very obvious.

 

[tkrfxr]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Yikes! There is rust everywhere...but that's kind of expected?
http://i939.photobucket.com/albums/ad237/fmrosell/DSCN1165.jpg?t=1269649562


There is no rust in the exhaust passages, they are nice and black...
http://i939.photobucket.com/albums/ad237/fmrosell/DSCN1144.jpg?t=1269649644

There is rust in the bolt threads and the gasket was flat, but not worn or corroded.
http://i939.photobucket.com/albums/ad237/fmrosell/DSCN1138.jpg?t=1269649683

 

[Don S]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Clean the gasket surface, then look at it. In your second picture, you are looking at the remains of the old gasket. Clean it up, then take a picture of the gasket surface.
From the looks of the other pictures, you have a very minor case of surface rust.
I could get the same thing by setting a brand new riser out in the rain for a couple days.

 

[Bondo]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Ayuh,... Amazingly clean for 6 years in Salt...

Riser looks to be clogging abit though...

 

[tkrfxr]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Thank you...I am relieved. I just saw the rust in the joint ant figured something was amiss.
http://i939.photobucket.com/albums/ad237/fmrosell/DSCN1139.jpg?t=1269651634

I did the joint cleaning on the manifold surfaces, and after getting rid of the rust, gave it a little Rust-oleum, into the passages....(I know, when it comes to salt water, "resistance is futile...")
http://i939.photobucket.com/albums/ad237/fmrosell/DSCN1163.jpg?t=126965211d

But the metal looks good. I just saw the post on the gasket sealant question...I got the Volvo OEM kit and it goes on dry, after a sanding with 80-grit, according to the instructions. The surfaces look flat, although on gross inspection only.

Thank you gentlemen.

 

[ENSIGN]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Since your using the old manifolds and risers a little permatex #2 won't hurt a damn thing...Good insurance

 

[Don S]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Since your using the old manifolds and risers a little permatex #2 won't hurt a damn thing...Good insurance

WRONG.......WRONG.........WRONG !!!!

You absolutely do not use any gasket sealer of any kind with the Volvo OEM gaskets. It even says so in the instructions that come with the gaskets.

 

[ENSIGN]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

WHY??? And don't tell me because thats what volvo said

 

[Fishermark]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

You also want to get rid of the paint where the gasket sets. I suggest taking a nice fine flat file and hitting a few times to an even texture.

 

[Don S]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

WHY??? And don't tell me because thats what volvo said

Well, to start with it's a metal shim gasket with a special coating on it. and in the instruction book it specifically states (In bold print) to not use sealer. See picture from instructions below.
Call me crazy, but I would rather do what Volvo (The designer of the gasket) says than what ENSIGN (member of a forum with unknown knowledge of the subect) says.

 

[tkrfxr]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

The job is done, and instructions were followed to the letter.

1. surfaces was sanded with 80-grit sandpaper, with care to remove residue from manifold gas exhaust passages.
http://i939.photobucket.com/albums/ad237/fmrosell/Riserust/DSCN1174.jpg?t=1269781604

http://i939.photobucket.com/albums/ad237/fmrosell/Riserust/DSCN1173.jpg?t=1269781702

2. gakets were applied dry

3. Torque was set to 26-29 ft-lb, with clean threads and bolts, as instructions recommend...

The finished product...
http://i939.photobucket.com/albums/ad237/fmrosell/Riserust/DSCN1180.jpg?t=1269781861

 

[Bondo]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Ayuh,... Looks Great,....

 

[tkrfxr]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

Ayuh,... Amazingly clean for 6 years in Salt...

Riser looks to be clogging abit though...

Now that I think about it...I use the Neutra-Salt flush system...

When I cleaned the water passages, the rust flakes had a sediment-rock-salt feel to them...maybe it's the salty residue left by the stuff...similar to what I found inside the raw-water side of the heat-exchanger...with chunks of the eroded pencil-anode...

Something to look out for, if you come across it.

 

[achris]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

WHY??? And don't tell me because thats what volvo said

Because the gasket IS the sealer, and what DON said....

 

[craze1cars]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

I'm bumping this old thread with hopefully a simple follow-up question. I've purchased this new-style Volvo gasket kit and am doing the exact same job right now on my 1999 Volvo 5.0 GL because I had to remove risers in order to pull rocker covers for a different project.

It all looks pretty simple/common sense. I have it torn apart, condition all looks similar to the pics shown in this thread...not excessively rusty. I chased all the threads with tap & die and cleaned 'em up pretty & smooth per instructions. Ready to assemble.

Just one question:

Volvo instructions recommend using a "spray-on gasket remover" to get the old gaskets of of the surfaces before block sanding with 80 grit. I don't have any "spray-on gasket remover."

Sooooo, tomorrow I planned to run to local auto parts store and see what I find. Before I go do that, can anyone recommend a specific product? One to avoid? An alternate recommendation INSTEAD of buying the spray-on stuff? It's hard for me to tell exactly what type of gasket is in there now...but it's definitely not the same as the new style. So I assume it is the original from 1999 assembly. It looks rather thin, silver-looking, it's on both surfaces, and it's stuck pretty good.

Volvo instructions recommend against mechanical scraping to avoid damaging surfaces.

Thank you in advance!!

 

[bruceb58]

Re: Bleeding rust in manifold-riser joints VP 5.7 OSXi-DF

You should start a new thread and put a link to the old thread. I read through this entire thread before I came to your post thinking the whole thing was new.