Leaking exhaust manifold gasket

[toyotafreak]

1. did you pressure test manifolds....

>Yes, today. Nice tip on using the boat's hose to adapt to the garden hose. No leakage. Ended up attempting to seal the water jacket exit at the exhaust to create some back pressure. Still no leaks inside manifold. That dent is bad news in the long run, as if the thing were to fail, that's where it will happen. At this point, the only functional problem with the manifold is I need to check flatness of the mating surface. It looks to me like the hit pulled the top surface away from the head a bit (hence the leaks are all up top).

2. need hull number to look at history

>TMMTD029C000 I'm second owner. Bought from the Edens brothers in Lewisville, TX in 2003.

3. That is not latent defect that is screw driver or prybar damage....

>The pictures must not tell the story. There's no way that damage happened while engine was installed in the boat.
 
4. drain oil into clear containers and see if milky or water on bottom

>Pulled my 3-week old Mobil 1 after about 50 gallons in fuel, and it's just its usual dark color with no evidence of water. Wreck probably heard my sigh of relief all the way from the EU. Drained into to clear 1g water bottles. I've left them upside down and will drain a bit from the bottom tomorrow night or so to see if any has collected down low.



The Edens never did any work on the boat themselves, and I know it spent some time in the dealership (MMDC flash, oil pressure sender, tower mounting, etc.). Here's a pic from June 2003 showing both dents.

[Capt Rick]

1. No warranty history of engine problem.
2  manifold damage Starb or Port

[toyotafreak]

Port side (fuel pumps below).

I'm all ears right now.

[Capt Rick]

Just to verify the engine serial number.
located on flat intake under thermostate and throttle body. Six digits ingraved. Starts with 8_____.
use flash light and powder - comet etc to clean to see better.

[toyotafreak]

Is this picture okay? I didn't see anything engraved.

Hopefully that one cylinder is just lacking spark. Doesn't explain the oil, though. Perhaps leaky valve guide?

[Capt Rick]

Remove flame arrestor. on flat metal intake pan cross member of block..

[cyclone]

It's not that unusual in my experience to see a little oil here and there. If you are USING oil that is a different story. Still not that big a deal as long as it's not fouling plugs all the time.

[toyotafreak]

Engine serial number is 825581.

Not sure what you're looking for, but I really think this is something Nichtern may help with. There are no scratches in the paint in the dents, and I swear it looks like somewhere between the engine plant (Japan, forgot the plant name) and Florida, the thing was hanging on a chain and was swung into something. Either that or somebody drove into it while on the crate. Either way, those manifolds are big bucks, and while I haveit opened up, should replace the valve cover before it starts leaking for real. That's a decent shopping list.

After taking off the intake, I remembered why every year or so we clean the butterfly valve on our Sequoias. The Epics need it done as well. I'll get the camera out this weekend and take some pics of the effort. Not a big edal, but there is quite a bit on buildup in there.

Thought I had to take the aft bulkhead out, so this baby's laid open. Time to wipe the bilge, grease the steering, change packing, replace the foil insulation, reglue the carpet, perhaps add a second bilge pump and run the second power/ground up to the dash.

Fact is, summer's here and we don't have a boat.

[wakejunky]

toyotafreak:

I would have to agree with you on its probably factory damaged. I can understand a large prybar putting a dent in the manifold  (they are fairly thin). But Lexus valve covers are cast aluminum and pretty thick. It would take some major force to dent the valve cover. Cast parts usually just break.
And what would someone be doing that need that large of a prybar in that area of the engine??? If so I would expect to see a large gouge on the bilge wall where the tip dug in. AHHH.....it still doesn't make sense!!   What were they trying to move?

[Capt Rick]

1. That is the factory serial number.
2. Is it posssible to contact Phill Dil Boats an look for warranty records, or if they did an alignment.
3. Is it possible someone tried an alignment and try moving the engine.
4. I really think that happened later there are too many inspections for that to go out from factory.
       

[toyotafreak]

I just got off the phone with Greg Gaudin from Phil Dill(972) 221-9767. I met him in 2003 and he let me look through the TMS documents. I had asked him at the time for the boat's maintenance records and he said he would release them after the Edens authorized him to do so. I contacted the Edens and they told me they contacted Gaudin to release the docs. I recall asking him about the docs sometime after that, but I didn't persist.

He told me today that they switched over to a new recording system in 2003 and that all prior records were archived off-site. He said it would take a guy several hours to go to the site and dig through the records. He's not going to volunteer to do that.

I don't believe there was any driveline work besides winterizing and fluids/filters/impeller. I believe they did get the packing changed. Phil Dill did install the tower (poorly) and replaced the MMDC or just burned it with new software. I'm not going to say that dfealership was particularly competent, and wouldn't be surprised if they did jack something up, but I just don't believe they ever had a reason to be in there.

I know the Edens would never have done an alignment on their own, considering the boat was under warranty until just before they sold it to me and the fact that it was brand new and they were never ones to wrench.

I've never done an alignment, and any person on this site would agree that if I had done it, I'd have written about it here (I wrote the v-drive annual maintenance presentation, a full accounting of the tower remounting I had to do, described in detail how the tracking fin installation went different than the service bulletin covered, etc., etc., etc.)

If I recall correctly, the ski pole support frame would've been in the way of a prybar slid down to wedge between stringer and manifold. I'll look at that aluminum bracket down at the stringer to see if there's any marks from a prybar.

[toyotafreak]

The manifold is way bent. Layed a straight edge across the bolt surfaces on each cylinder. It's clear that the upper four bolt holes are bent outward.

Also shown below is an aluminum angle stock which had broken its spot welds sometime back in the day. I don't know if maybe that's just used as a positioner for the engine mounts into the stringers, but one thing it does do is hold the fuel/water separator. Sometime prior to 2003, several screws were used to reattach the angle to the floor, probably so the fuel filter would stay upright. No idea when or how or why it broke in the first place.

[toyotafreak]

Una mas.

[masonlk]

Could be no warranty issues because of negligence on the prior owners part. You might want to consider having a marine surveyor take a look at your boat. He might be able to find the cause for all the damage and advise you on repairs to make sure you don't have any recurring problems.

If you welded everything back to it's original position would it all be out of alignment?

Put a straight edge to the machined engine exhaust ports to check for any damage.

Any sign of bottom damage? New bolts on trany/engine connection or other parts of the driveline?

[toyotafreak]

Good points, I'll look around. Don't suspect that they ripped the driveline, but will look around.

That piece of frame that's cracked is either cosmetic or just used for initial positioning of the engine mounting frame or else they would've at least run a full bead down the length. At some point I should check alignment, but the thing's smooth so I assume it's not way out.