Volvo Riser Gaskets

[rwidman]

I posted a problem several months ago where water would seep into the cylinders over a period of several days of non use (2003 Volvo 5.0). The spark plugs would be wet and the engine would not start. I never solved the issue, but draining the manifolds after each use has allowed me to use the boat.

I came across a similar issue on another boating forum where the poster suggested that the manifold to riser gaskets were leaking and that Volvo had issued a service bulletin and redesigned the gaskets.

Has anyone heard about this and can anyone provide additional information?

 

[Don S]

Re: Volvo Riser Gaskets

Volvo did change the gaskets. Here is the wording from the SB.
The new gaskets are a lot different, they do not use any sealant or they will leak. IF you don't install them per instructions they will leak. But when they are installed correctly, I haven't had any problems.
Funny thing is, I have been installing them for a couple of years now, and the bulletin is a 2006 bulletin.......
As a rule of thumb on any exhaust riser gaskets. Merc, OMC or Volvo. If you see evidence of leakage on the outside of the manifolds, replace the gaskets and inspect the gasket surfaces. If it leaks on the outside, it has just as much chance (if not more) to leak on the inside where the biggest heat change is done.

Here is the Service Bulletin:

During our routine audit processes, we have noted a potential for water entering the engine through the exhaust following an overheat condition. This can be traced at times to the loss of proper torque of the
high-rise exhaust elbow. The expansion and contraction during and following an overheat condition can
cause distortion to the gasket and prevent proper sealing.
It is our recommendation that when servicing an engine that has been overheated, the high-rise exhaust
elbow gasket(s) should be replaced with gasket P/N 3863191 (V-6 & V-8 ). The following procedure supersedes
the procedures that are outlined in the workshop manual under “High-Rise Exhaust Elbow Replacement.”
50347
Information for replacing the gasket are provided in the Installation Instructions entitled “Exhaust Riser
Gasket, V-6 and V-8” (PN 7742588 ).
NOTE! When replacing this gasket, be sure to follow the directions exactly as described in the Installation
Instructions.

 

[bjcsc]

Re: Volvo Riser Gaskets

I used the new gaskets for a season and then switched back to the old style. I don't trust or like the new style, Basically, they are a thin sheet of some metal (al maybe) with a teflon type coating on them. They use no sealant, but have a couple of raised ridges than run along the sealing path. You absolutely can not disturb the coating, i.e. slide the riser on the manifold, etc.. There was too much room for error with them for me...

 

[Don S]

Re: Volvo Riser Gaskets

You can't buy the old gaskets anymore, unless they happend to order a million of them, the old style aren't even made anymore. So you better get used to using them.
When done correctly, they seem to work better than the old ones from what I see.

 

[bjcsc]

Re: Volvo Riser Gaskets

Regarding the gaskets there are lots of quality aftermarket gaskets that fit for me. That said, hearing you say they seem to work better means more to me than what Volvo says. I only have myself to compare to, they make them, but you see a lot.

Regarding this guys situation, I would assume his riser/manifold setup it similar to mine. I can't see how it could be responsible for "seeping over a period of several days". The joint is higher than the water level in the engine and water drains to only the manifold on shutdown. At least on my 4.3GS it does...

 

[rwidman]

Re: Volvo Riser Gaskets

Regarding this guys situation, I would assume his riser/manifold setup it similar to mine. I can't see how it could be responsible for "seeping over a period of several days". The joint is higher than the water level in the engine and water drains to only the manifold on shutdown. At least on my 4.3GS it does...

My engine has the flush hose that is used with the engine not running. Does it matter that I extended the hose up and through the transom (near the top) to make it easier to use? This woiuld put the hose end above the top of the engine by 18" or more. Or does the water drain out anyway? Is it possible that my household water pressure is too high?

There was no problem for the first three years, it started all of a sudden. Also, I checked the bolts that connect the risers to the manifolds and they were much looser than the specifications in the service manual. I brought them up to spec but haven't let the engine sit without draining the manifolds to see if this helped. I don't believe the engine has ever overheated and there's probably less than 200 hours on it.

Don, I would bring it to you for repairs in a minute, but I think it's about an 8,000 mile trip each way! Thanks for the service buletin and other info.

 

[Don S]

Re: Volvo Riser Gaskets

Change the gaskets, and you will probably find your problem goes away. Also inspect the gasket surface of both the manifold and riser. It's also possible you have a cracked manifold or riser, but I would definatly replace the gaskets and try it.
You may not have had an overheat, but the bolts were loose indicating a problem.
The longer flush hose won't cause a problem.

 

[rwidman]

Re: Volvo Riser Gaskets

Thanks Don.

I don't really suspect a cracked manifold or riser because it happens on both sides of the engine.

As for difficulty, is this just a "remove and replace" DIY job for someone who does minor mechanical repairs, can follow instructions, and is reasonably competent or is it something for a trained mechanic?

Are the installation instructions included with the gasket set or are they a seperate part #?

BTW: This all started after I had the 100 hr check done at an authorized Volvo service center. I took it back to them and they are the ones that found the water on the plugs (the first time, I'm a quick study). They couldn't figure out how this was happening. I would have thought they would be up on the service bulletins and would have suggested changing the gaskets. Makes me wonder.

 

[Don S]

Re: Volvo Riser Gaskets

It's just 4 bolts and a hose clamp. The instructions come with it. That gasket kit part number contains 2 gaskets and the instructions.

 

[rwidman]

Re: Volvo Riser Gaskets

Thanks Don, I'll find a source and order it.

 

[bjcsc]

Re: Volvo Riser Gaskets

BTW: This all started after I had the 100 hr check done at an authorized Volvo service center. I took it back to them and they are the ones that found the water on the plugs (the first time, I'm a quick study). They couldn't figure out how this was happening. I would have thought they would be up on the service bulletins and would have suggested changing the gaskets. Makes me wonder.

Let me guess: Superior Diesel...

Changing the gaskets is easy. (Dealing with your exhaust is the hardest part) When you remove the risers, It's a good idea to clean the threads on the bolt with a die, and the holes in the manifolds with a tap or chaser. You can buy chasers, or grind the taper (the 1/4" or so at the tip) off of a tap. Blow the holes out afterwards. This will give you a more accurate torque reading. Be careful not to break the tap/chaser off in the manifold. Should be 3/8 16.

 

[rodbolt]

Re: Volvo Riser Gaskets

another tip, carefully check the surface flatness of both riser and manifold surfaces. the new shim type gaskets work very well but only if the surface is flat and in the service specifications provided with the gasket kits.
you can use a medium or fine mill file to flatten the surfaces. most of them have high spots at the bolt holes in the manifold.

 

[rwidman]

Re: Volvo Riser Gaskets

Let me guess: Superior Diesel...

No, a marina on the Ashley river named for an air breathing sea creature common to the area.

The other Volvo authorized shops in the area refused to service my boat because I didn't buy it from them or store it in their marina.

Thanks, everyone for the help. Gaskets have been ordered. We will see.

 

[Buttanic]

Re: Volvo Riser Gaskets

Let me guess: Superior Diesel...

No, a marina on the Ashley river named for an air breathing sea creature common to the area.

The other Volvo authorized shops in the area refused to service my boat because I didn't buy it from them or store it in their marina.

Thanks, everyone for the help. Gaskets have been ordered. We will see.

I am always amazed how businesses will kick dollars out the door because "You didn't buy it from me". I wish I had that much money.

 

[bjcsc]

Re: Volvo Riser Gaskets

No, a marina on the Ashley river named for an air breathing sea creature common to the area.

The other Volvo authorized shops in the area refused to service my boat because I didn't buy it from them or store it in their marina.

Ha! DC (I guess you don't want to name names) is who brought me to this forum. I've had mixed experiences with them, but this past spring when they couldn't get my timing set right or diagnose what ended up being a bad dist. cap I had enough. Found this forum out of frustration.

What other Volvo service shops did you find? AFAIK, DC and SD are the only ones around. SD has a tremendous rep. on diesels, but they don't really do so well with gas. Both are good places to buy parts from. I have a good tip for you: Most of these places get their Volvo parts through Jerry's Marine (wholesale/distributor - don't even bother calling). If you find a shop nearby - any kind of shop that orders from Jerry's you can get anything. I order mine from Jerry's through Ross Marine as they are right around the corner from me. Anyway, good luck on the risers...

 

[rwidman]

Re: Volvo Riser Gaskets

AFAIK ? Don't know that one.

The Volvo site listed Duncans. I launch next to them at the public ramp. I made a service appointment with them but they called back the day before the appointment and cancelled for the reasons I quoted above. Another on the Volvo site was (if I remember correctly) Seel's on rt 17. They declined also but recommended DC. The folks at DC are very friendly and seem to know what they are doing but I'm surprised they didn't think of the gaskets.

 

[bjcsc]

Re: Volvo Riser Gaskets

As Far As I Know...

Seel's used to be a parts dealer, they are no longer. They have nothing. Duncan's is a sales dealer, and I think they only handle warranty work and may farm that out. Anyway, if you get jammed up on anything feel free to PM me seeing as we're near each other...

 

[rwidman]

Re: Volvo Riser Gaskets

Thanks.