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

mart284

Seaman
Joined
Aug 22, 2024
Messages
71
Heads are good and tested - will try to make better pictures with proper light. Those were done in the dark below the boat. Water part was pressure tested and each valve separately tested for leaks. IRL they are good and nice. On Friday will try to go to the boat and unwrap them and make better pics..
 

cyclops222

Commander
Joined
Mar 21, 2024
Messages
2,248
Well it sure looks like a VERY defective master mold at the manufacturer.
He is delighted with the recent demand for those manifolds.
Oh well.
 

tank1949

Lieutenant Commander
Joined
Apr 4, 2013
Messages
1,911
My setup looks very similar to the drawing attached - will go over it pipe by pipe once in the boat. Thanks!

Cyclops - Searay has rather big mufflers and it is not the issue with fast stopping, I am sure I have the issue with water flow around this one exhaust manifold - it started after the engine removal for the maintenance last winter. Just need to figure out, what is now different from last seasons...cracked manifold and engine bay
add y pipe flappers and/or increase exhaust manifold thickness by double the gaskets. Your manifold or head may not be perfectly flat. However, I suspect Y pipe shutters (flappers) will reduce cold water entering an exhaust system.
 

mart284

Seaman
Joined
Aug 22, 2024
Messages
71
Went to the boat today and made a short clip of the heads, here you go:


Should not be the issue that they are so bad. Will replace the springs. And all the contact plates are nice and straight - all measured and checked.
 

cyclops222

Commander
Joined
Mar 21, 2024
Messages
2,248
I give up on a repetitive same exact spot failure. Engines get REPEAT ...HYDRO LOCKS. I was on a cruise. I pulled the plugs and cranked t the engine to blow out water. 3 times on the cruise. No detectable damage to any of the engine parts.
Get a different manufacturer !!!
 

mart284

Seaman
Joined
Aug 22, 2024
Messages
71
I give up on a repetitive same exact spot failure. Engines get REPEAT ...HYDRO LOCKS. I was on a cruise. I pulled the plugs and cranked t the engine to blow out water. 3 times on the cruise. No detectable damage to any of the engine parts.
Get a different manufacturer !!!
Sorry to disappoint you - Searay Sundancer has a muffler in the middle so there can not be hydrolock from water getting in from exhaust. Exhaust pipes are on the side of the boat hence sudden stop will not get the water in. I am not sure how other boats are done, but this IS NOT the issue here. No repetitive comments required from you on the same topic :)
PS - 2 different manufactures were used already on manifolds..
 

mart284

Seaman
Joined
Aug 22, 2024
Messages
71
So! 3 trips made and it seems to be fine now.
What was done and what fixed it - I have no F***ing clue:)
New valve springs, heads done, all new gaskets, left and right side heads were swapped, new manifold. Engine is running better and not so big difference between port and stb engine anymore on power of consumtion on idle or under 3800rpm. I do hope that all is good now and this summer my main concern is petrol price :) Thank you for your support!2025-05-28 16.23.19.jpg
 

Scott06

Admiral
Joined
Apr 20, 2014
Messages
6,902
So! 3 trips made and it seems to be fine now.
What was done and what fixed it - I have no F***ing clue:)
New valve springs, heads done, all new gaskets, left and right side heads were swapped, new manifold. Engine is running better and not so big difference between port and stb engine anymore on power of consumtion on idle or under 3800rpm. I do hope that all is good now and this summer my main concern is petrol price :) Thank you for your support!View attachment 408613
this one had us all stumped... one thing maybe that wasn't looked at is if the igntion timing was late/retarded temps can get hot especially exhaust gas.

Maybe something to verify total advance is ok.
 

mart284

Seaman
Joined
Aug 22, 2024
Messages
71
this one had us all stumped... one thing maybe that wasn't looked at is if the igntion timing was late/retarded temps can get hot especially exhaust gas.

Maybe something to verify total advance is ok.
It was checked as well - and was OK. Consensus here seems to be linked to dead valve springs - during 3000 rpm excaust valve stayed mostly open and overheated that one spot, when cooling down with sea water, it made it crack

All manifolds were faulty in the same spot.

I do hope that it will now run smoothly for the whole season:)
 

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Lpgc

Petty Officer 1st Class
Joined
Jun 17, 2023
Messages
299
Pleased for you @mart284 :)

I suppose a dead valve spring could lead to localised overheating around that exhaust port, this (valve float) could also account for this engine being down on power at 3000rpm compared to the other engine. Still I'm a bit surprised there'd be enough extra heat to cause the marine exhaust to crack.

But might expect the valve to get burned and compression to be down on the effected cylinder which would be a pointer to a head problem?
 

mart284

Seaman
Joined
Aug 22, 2024
Messages
71
Pleased for you @mart284 :)

I suppose a dead valve spring could lead to localised overheating around that exhaust port, this (valve float) could also account for this engine being down on power at 3000rpm compared to the other engine. Still I'm a bit surprised there'd be enough extra heat to cause the marine exhaust to crack.

But might expect the valve to get burned and compression to be down on the effected cylinder which would be a pointer to a head problem?
Well, we did check the compression on cold engine and all was good, also no major visible burns, however it was always flooded when heads came off...

I will let you know, if I am that happy in September :)
 
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