Hi everyone,
Need some suggestions here as my best friend and mechanic and I are out of ideas.
I purchased a 2007 Bayliner 192 Cuddy last July. It ran fine all summer. However, I did notice a slight leak at head gasket( external) over the side cover. The boat was never overheated when I was running. So, this June we pulled the head. Checked it out and no warp. Fixed a couple of valve seats and checked all valves. All surfaces within spec. Put it all back together by the book, and it ran like a top in the yard. No leaks no issues. However, when I popped her into the water, and under load, as soon as I got her up to about 3000RPM, I heard exhaust leak noise coming from manifold. I pushed her a little too hard and the noise all of a sudden got super loud. I could feel air under the manifold at the middle 2 exhaust ports.
Took her back to yard and mechanic and I took off the manifold. We could see that the manifold blew out exactly in the area I felt, and it was the 2 center exhaust ports. We also noticed, that the head gasket buckled in that same area. We took the head off, and inspected. The head gasket blew out in the same spot as the manifold(externally). Luckily, no damage or water got into the motor.
Got new gaskets and checked the head again and put that back together. I noticed on the manifold, that we missed a spot of corrosion right at the 2 exhaust ports where the gasket blew out. With flat edge I could see a slight wobble there. It was hardened rust and flaked off once we hit it tool. Cleaned it all surfaces well and all was good and true on the manifold and head.
Put it all back together again. All snugged up according to book. Ran in yard on hose, ran like a top.
Took it back out in the water, and I will be dammed. Leaked in the same spot under load.
I do not understand why. Everything is torqued to spec. All surfaces flat. As soon as it gets up to about 2800 Rpm the exhaust starts to leak and it is loud.
I have not pulled the manifold again to check the head gasket. I ran it slow yesterday at about 2700 rpms and no noise.
Do I just replace the manifold? Do I resurface the manifold? It is not leaking, it is not cracked. The boat was mostly used in freshwater in NC. I used it in Saltwater last season.
Any ideas out there?
Thanks
Mark
Need some suggestions here as my best friend and mechanic and I are out of ideas.
I purchased a 2007 Bayliner 192 Cuddy last July. It ran fine all summer. However, I did notice a slight leak at head gasket( external) over the side cover. The boat was never overheated when I was running. So, this June we pulled the head. Checked it out and no warp. Fixed a couple of valve seats and checked all valves. All surfaces within spec. Put it all back together by the book, and it ran like a top in the yard. No leaks no issues. However, when I popped her into the water, and under load, as soon as I got her up to about 3000RPM, I heard exhaust leak noise coming from manifold. I pushed her a little too hard and the noise all of a sudden got super loud. I could feel air under the manifold at the middle 2 exhaust ports.
Took her back to yard and mechanic and I took off the manifold. We could see that the manifold blew out exactly in the area I felt, and it was the 2 center exhaust ports. We also noticed, that the head gasket buckled in that same area. We took the head off, and inspected. The head gasket blew out in the same spot as the manifold(externally). Luckily, no damage or water got into the motor.
Got new gaskets and checked the head again and put that back together. I noticed on the manifold, that we missed a spot of corrosion right at the 2 exhaust ports where the gasket blew out. With flat edge I could see a slight wobble there. It was hardened rust and flaked off once we hit it tool. Cleaned it all surfaces well and all was good and true on the manifold and head.
Put it all back together again. All snugged up according to book. Ran in yard on hose, ran like a top.
Took it back out in the water, and I will be dammed. Leaked in the same spot under load.
I do not understand why. Everything is torqued to spec. All surfaces flat. As soon as it gets up to about 2800 Rpm the exhaust starts to leak and it is loud.
I have not pulled the manifold again to check the head gasket. I ran it slow yesterday at about 2700 rpms and no noise.
Do I just replace the manifold? Do I resurface the manifold? It is not leaking, it is not cracked. The boat was mostly used in freshwater in NC. I used it in Saltwater last season.
Any ideas out there?
Thanks
Mark
