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  1. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    ECM are not yet swapped Water pump, map sensor, thermostat housing are swapped Both head went to refurbishing after hydrolock and new good gaskets were installed afterwards
  2. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    I took one manifold for testing and it was confirmed that crack is thru the metal and water was escaping. Visible crack is always there. Can take the next one also to the test to verify once more - that job is not too costly I have sea water cooling, so no closed cooling part and head leak does...
  3. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Sadly exactly the same issue was here in 2015, but the guy never wrote the solution :( https://forums.iboats.com/threads/2003-mercruiser-6-2-mpi-exhaust-manifold-cracks.662180/
  4. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    I can not see the outgoing side of the water as it exits thru elbow and back to the sea. I can only see if water is going to the spacer in my case and to the bottom of the manifold. And I am sure that waterflow is there - manifold outside temp on idle and on the run is similar to other 3...
  5. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Oil with water is milky stuff - confirmed.
  6. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Bilge is dry, I have no leaks on my old Searay :) only cracked manifolds....
  7. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    no- what do you mean by that? from the restainer towards the waterpump or somewhere else? I am pretty sure that there is enough water and flow is good - at least both engines are pumping same amount of water out
  8. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Hi The issue started this summer and engine was removed by me and mechanic due to the oil leak from the bottom of the engine. Me, myself and I are the three guys draining my wallet :) Selling the boat with the error would make me an a**hole and I do not want to be that guy. I have booked the...
  9. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Water from from the bottom of the boat inlet until the exit is clear - same amount of water is going thru both engines. Water pump, thermostat casing swapped between engines. New impeller and thermostat added.
  10. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Searay has a muffler and water / exhaust outlet is on the side of the boat, so stopping will not be an issue. I have spacers between the elbow and manifold, so it is as high as it could be
  11. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Sierra and Recmar, both last few trips, rest of the boat is with Recmar Yes, did not test it with laser on the bench but with light and straight ( can not figure out, how this is called in English) tool it was perfect We use torque wrench, should be as required We swapped thermostat housing...
  12. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    All the cracks are in the same area, so it might me linked to the cylinder somehow. After waterlock (2 manifolds ago) engine was taken to small pieces and all good parts were put back. New head gasket, heads refurbished and measured to pressures on all cylinders - all good. Only thing still not...
  13. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Compression check was done twice - once after the first crack and second time after bent rods were changed and valves were redone - all good there
  14. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    One idea from the field - can this be linked to faulty injector on that cylinder? Low on fuel and burning too hot causing manifold to crack?? I will measure fuel pressure and take the injectors for checkup next week.
  15. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    And all 5 cracks are on 5th cylinder
  16. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    YES, visible crack and went to the shop to test it with pressure, bubbles were coming thru from the crack in watertank
  17. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    on the positive note - manifold change is doable now within 1,5 hours:)
  18. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Update and what was done: - new manifold obviously:) with new thingy with ball inside for 2 pipes to connect in the bottom of the manifold, also checked the surfaces, no bends or irregularities - checked water flow, cleaned filter (did not find any debris inside) - checked all the water pipes...
  19. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Both engines are having pipes in the exact same manner. Restrictive seal is under the water hose. As I am still waiting for manifold to arrive to Estonia, I did not do the hose checks. Also new thingy where 2 water lines are connected below manifold is ordered, if that ball there got stuck on...
  20. M

    2002 5,7 Mercruiser exhaust manifold keeps cracking - 5 times this summer

    Thanks! New manifold will reach me this week and before dismantling will check water flow on all the piping. If there is water freely flowing, what next? I assume I should find a bad hose somewhere...
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