2003 Volvo Penta 4.3GL-C Intake Manifold Cracked Due To Freezing- Milky Oil On Engine

2003lsr

Seaman Apprentice
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Apr 10, 2011
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39
Disclaimer: Let me say "I did winterize by the book". No step in my owners' manual mentioned intake manifold plug removal (behind alternator tensioner) during winter preparation.
Situation: Boat stayed at the marina in a lift slip this winter. Sunday before last was beautiful here in East TN, so we decided to go for a cruise. Upon arrival at the boat, removed covers and checked the oil. Oil (normal color) was a bit high on the dipstick, but I figured it was just the attitude of how the boat had been sitting on the lift. In retrospect, I should have wiped the dipstick again and rechecked level. Anyway, she cranked up fine. Idled until warm, then "no-waked" out to main channel. Hit the throttle and it ran great for 10 seconds or so, then sputtered and died. Popped the hood and saw the "milkshake" on top of the intake manifold. Brought the boat home, and during disassembly, discovered a 4" freeze crack in the intake manifold. After vacuuming out the lifter valley and wiping it down, I did a thorough inspection for block cracks (around lifter housings) and elsewhere. The oil/water mix was in the cylinders as well. Compression test prior to disassembly revealed extremely high readings due to the liquid in the cylinders. Ordered a new factory intake from MichiganMotorz.com today ($189.00 + $20.00 for gasket set). Waiting on all parts so I can reassemble and take it to the lake. Lessons Learned: 1) Read these forums throughout the year. I've learned more in the past weeks about specific problems than I ever knew before. 2) Follow manual when winterizing, but also, think out of the box, "could water be in there", if the answer is yes, read some more and figure out what needs done so you don't end up with something cracked. 3) Service Bulletins- SEEK THEM OUT!! Anyway, I've enjoyed reading posts from very knowledgeable folks, and people with similar stories. This forum is a powerful tool! Thanks!
 

Bondo

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71,082
Re: 2003 Volvo Penta 4.3GL-C Intake Manifold Cracked Due To Freezing- Milky Oil On En

Ayuh,... I donno why Volvo has that Issue, as everybody else's intake manifolds tend to drain With the block, through the block drains...
 

2003lsr

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Apr 10, 2011
Messages
39
Re: 2003 Volvo Penta 4.3GL-C Intake Manifold Cracked Due To Freezing- Milky Oil On En

Bond-o, that's a good point you make. The 4.3GL intake manifold only has two water ports (located at the forward sides). If the bow of the boat is higher than the stern, water will remain in the back of the intake manifold (regardless of whether the plug is removed or not). There are two additional water ports on the rear of the cylinder head, however, the intake manifold has no openings there. The water channel on the intake manifold only goes about three quarters of the way back, not all the way. Not sure if other models are set up the same way or not?
 

Lou C

Supreme Mariner
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Nov 10, 2002
Messages
13,025
Re: 2003 Volvo Penta 4.3GL-C Intake Manifold Cracked Due To Freezing- Milky Oil On En

see this OMC TSB on the square plug that has to be removed to drain late model 4.3s...must apply to Volvo too....I have looked a few Volvo manuals and found them to be vague and poorly translated, suprising for a company who has been in the biz as long as they have and has been building drives here since the joint venture with OMC. OMC's manuals on the other hand were excellent....

http://www.marinemechanic.com/omc/4155.htm
 
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