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TOPIC: 1984 Contessa exhaust boot & possible water leak

1984 Contessa exhaust boot & possible water leak 31 May 2017 15:37 #1

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Hi all,
Been surfing the site and getting great info. Now I have a couple questions. took our 1984 Contessa 2850 with Volvo Penta 4.3 for a spin on our madden voyage. She ran for a couple hours about , just looking at the scenery on shore. Got to the end of the lake spun around to head back to the dock and opened her up to 17/18 mph for about 20 min then hear change in tone from the rear, out the back. Smoke started filling the cabin & coming out the throttle controls. After checking the wiring, which the smell was like rubber or electrical wiring all was fine under the dash. Looked in the engine compartment to find 1 of the exhaust boots had nice size hole melted in it. We duct taped it up and putted back to the dock. Did want to strain the tape.The next day I started to remove & replace the boot & its rock solid & the other one has a small hole in it to. Is it best to pull exhaust manifold, because it don't seem I could get them off with out cutting them up or put them back on with that small a gap. Is it possible they just broke down from age? I also noticed some water below water pump. Maybe 1in or so.The guy we got it from replaced the raw pump impeller but not the circulation pump. What's best way to test the pump? I've been told I can get a heavy duty Chevy water pump to replace it, is this a good idea?
Thanks,
Dale

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Last Edit: by Domenico. Reason: duplicate pic, was suppose to have 2 different ones.

1984 Contessa exhaust boot & possible water leak 31 May 2017 15:41 #2

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Couldn't post second pic. I have one, not so great, of water.

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1984 Contessa exhaust boot & possible water leak 31 May 2017 16:04 #3

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DO NOT continue operating the engine until this has been corrected!
Some portion of your seawater system is not working correctly. Start at the stern drive and work your way forward.

Those are your 95mm exhaust-elbow-to-Y-pipe couplers.
You will want to order 95mm soft wall exhaust hose, and about 2" longer than each of the OEM couplers.


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1984 Contessa exhaust boot & possible water leak 31 May 2017 16:37 #4

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Thats a lot of boat for a 4.3! Sounds like you have a plugged manifold or riser. As 2850 Bounty said check out the water flow. Overheating and a fire are possible unless corrected.
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1984 Contessa exhaust boot & possible water leak 31 May 2017 16:48 #5

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Thanks, I want to get those boots off so I can check out in there. Can I reuse the manifold gasket? It looks like that's the way to get to removing & replacing those boots.

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1984 Contessa exhaust boot & possible water leak 31 May 2017 17:11 #6

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1984 Contessa exhaust boot & possible water leak 31 May 2017 21:25 #7

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Here's a few pics

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1984 Contessa exhaust boot & possible water leak 31 May 2017 21:39 #8

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Tried to upload some others but keeps saying upload failed.

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1984 Contessa exhaust boot & possible water leak 01 Jun 2017 04:59 #9

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The Volvo 260A is a 5.7 V8. Your pic size maybe exceeding the file,size limit here on the BOC. Also your wiring down in the bilge is a bit ugly, and wire nuts are really bad form on a boat as well as not adhering to wiring requirements.
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1984 Contessa exhaust boot & possible water leak 01 Jun 2017 08:21 #10

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X2 on the 5.7. You can and should pull the risers not just to create the slack to replace the exhaust hoses but also to check for restrictions in the water jackets. It's very common for rust to build up to the point of cutting off the raw water flow into the exhaust system. Often the first indicator is the engine will warm to a normal operating temperature, then after a time there will be a second rise of 10-20 degrees. You can soak the risers in muriadtic acid to boil out the rust, but usually by the time you get done cleaning the chambers you will find they are shot anyway. Do not operate the boat until you have this repaired and do not reuse the gaskets. Btw, in my experience, the marine gaskets are often of different materials than the automotive ones to compensate for the engine being constantly under load, always pulling a trailer up a steep hill so to speak.
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1984 Contessa exhaust boot & possible water leak 01 Jun 2017 14:49 #11

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Check the waterneck, waterneck bushing, washers, o-rings ($30-40 parts), while you are servicing.. If they are marginal and you are breached and sucking in air... this will definitely take out the wet exhaust tubes.
I found out the hard way, was fine putting around, happens when the boat planes out and drive is out of water.

I believe I read in the Heloc guide that these are a 3 yr service part: if someone knows better please correct me if i am wrong.
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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 13:42 #12

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Thanks for all your input. I knew I had little work to do when we got it but nothing major. I have some heat tube to replace the wire nuts and have the additional parts ordered. Tearing manifold off this weekend to clean them up to put the boots back on when they arrive. I want to make sure it's sea worthy before putting it in the Slip.I'll post the progress & try getting the other pics up.
Thanks again

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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 13:52 #13

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Dale, the two rubber units that you are referring to are 95mm soft wall exhaust "hoses"...... not boots!
A good marine hose supplier can bring them in for you.
Make DANG sure that you order these 2" longer than the OEM 95mm soft wall hoses!
You'll learn why later!

Dale, NO on the automotive engine circulating pump.
Your Engine is Raw Water Cooled, of which means that you want a Circ Pump with the bronze or SS impeller and the special ceramic seal affair........ in other words, the Marine Version!


Dale, your post #1 refers to a 4.3L engine, yet your photo shows an AQ 260A

Also, your AQ 260A engine does not have exhaust Spacers/Risers....... you will have exhaust Manifolds and Elbows only! (no spacer or riser is available for this exhaust system!)

You also show a Johnson crankshaft seawater pump. I cannot tell for certain, but I believe that this would be the F5B-9 pump. If so, you will use the 1027B impeller.

My suggestions:

Drain the drive gear oil and catch and inspect it.
Pull the transmission ONLY.
Examine the interior area of the flywheel cover "snout" (inside of the bellows area).
Examine the universal drive shaft bearing crosses (aka U-joints to some)
Replace the water neck fitting and the special beaded gasket underneath it. (this is a wear part and must be routinely replaced)
Replace shift cable at this time if need be!
Replace drive shaft bellows when going back together.

DO NOT re-use any O-rings! Use NEW OEM or Sierra OEM equivalent!

I would strongly suggest replacing the PDS bearings. However, this requires engine removal or at least turning it side-ways!
Do this once, and you'll be good for another 15 years or so!

Clean up your wiring. NO wire wing nuts!

DO NOT store the stern drive in the UP position!!!!!

Remove the seawater pump impeller during winter lay-up!
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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 13:56 #14

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Domenico wrote: Thanks for all your input. I knew I had little work to do when we got it but nothing major. I have some heat tube to replace the wire nuts and have the additional parts ordered. Tearing manifold off this weekend to clean them up to put the boots back on when they arrive. I want to make sure it's sea worthy before putting it in the Slip.I'll post the progress & try getting the other pics up.
Thanks again



I would caution you against using wire connectors with the heat shrink tube attached to the fitting.

If at all possible, warm the engine up some prior to cracking the exhaust manifold bolts loose.
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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 14:47 #15

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Is this the gasket for the riser box I need?
www.ebay.com/itm/5-7L-350-Volvo-Penta-Ex...AOSwBahVdrg6&vxp=mtr

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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 14:57 #16

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Yeah sorry about my terminology, just getting used to all the lingo & actual names of things.
Thanks again so much!!

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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 15:01 #17

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As said.... (and even though you will see the term "Riser" being used), the AQ 260 does NOT use spacers/risers........ never has and never will!
If such a spacer/riser existed, and if one was to be used, the "elbow" would now mis-align with the exhaust Y-pipe!
Rest assured that the AQ 260 uses an exhaust manifold and elbow only.


Look here for the OEM gasket part number.

www.marinepartseurope.com/en/volvo-penta...744020-26-17911.aspx

This will show you the configuration of the seawater transfer ports and consequently the manifold-to-elbow gasket style.
www.iboatsimages.com/mall/image/view/2/7/781_2.jpg

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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 15:45 #18

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Bounty, gotta love nomenclature. I agree there is no spacer between the elbow and the manifold. In my experience, we called the spacer the spacer, and a water/exhaust mixing manifold that is above the exhaust manifold a riser. It's probably just local vernacular which is why I love seeing a picture of the part and be able to point to it and say "that thingamajig right there".

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1984 Contessa exhaust boot & possible water leak 02 Jun 2017 17:36 #19

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Pcpete wrote: Bounty, gotta love nomenclature. I agree there is no spacer between the elbow and the manifold. In my experience, we called the spacer the spacer, and a water/exhaust mixing manifold that is above the exhaust manifold a riser. It's probably just local vernacular which is why I love seeing a picture of the part and be able to point to it and say "that thingamajig right there".


I hear you..... and I call it "the dumbing down of America"!





:)

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1984 Contessa exhaust boot & possible water leak 09 Jun 2017 12:04 #20

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Morning All, after a long week I was able to get to working on the exhaust manifolds, cleaned them up & cut hose to 8 & 1/4" length with new T bolts & gaskets. Now I want to remove transmission & service it. The bellows are dry rot & there's a flat O ring that is tore up just what I see on the outside. Where can I find the part numbers & an exploded view of the parts I'm going to need: U-joints ,water neck fitting and the special beaded gasket, Both of the bellows, any O-rings, PDS bearings etc. or if there's any thing else I may need. Where can I find an exploded view picture with the part numbers I will need. I did say the motor was a 4.3 due to that's what the guy at the Marina told we when I was trying to find exhaust parts.
Thanks for all the help.

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1984 Contessa exhaust boot & possible water leak 09 Jun 2017 14:23 #21

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Bountys post #17 above linked a great resource
www.marinepartseurope.com/en/volvo-penta...744020-26-17911.aspx

many EVDs find your correct drive 270/275/280/ etc

This is a link i saved for my setup
www.marinepartseurope.com/en/volvo-penta...744020-44-17975.aspx

I got my bearings and crosses from "Beary Bearing/Motion Industries" All SKF

The marina guy is dead wrong that 260A is a 5.7l/350ci GM I had the exact same motor
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1984 Contessa exhaust boot & possible water leak 09 Jun 2017 14:52 #22

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Domenico wrote: Morning All, after a long week I was able to get to working on the exhaust manifolds, cleaned them up & cut hose to 8 & 1/4" length with new T bolts & gaskets. Now I want to remove transmission & service it. The bellows are dry rot & there's a flat O ring that is tore up just what I see on the outside. Where can I find the part numbers & an exploded view of the parts I'm going to need:
What you are calling a black flat O ring is an OEM "V-ring seal", and will be specific to your model collar steering fork.
If you have a 275, 280, 285 it will be OEM p/n 839195. You may as well replace the two bushings while in there.

You can find your part numbers by engine model number and by going here >
www.marinepartseurope.com/en/volvo-penta...GasolineEngines.aspx

U-joints ,water neck fitting and the special beaded gasket, Both of the bellows, any O-rings, PDS bearings etc. or if there's any thing else I may need. Where can I find an exploded view picture with the part numbers I will need?
If you are looking for part numbers by engine model number (via the MarinePartsEurope site), these will be OEM p/n's.
www.marinepartseurope.com/en/volvo-penta...GasolineEngines.aspx

The "bearing crosses" (what you are calling U-joints) can be a Spicer 5-1306-X. No need to buy these via Volvo Penta!
The PDS bearings and seals are industry standard, and can be purchased from a major bearing supplier at a fraction of what V/P would charge.
Bearings are a 6206 and a 6007. NO Chinese bearings...... period!!!!!! Use US, Japanese, German, etc.
The single lip seals are 35x62x7mm in Timken or TCM.
Do not forget to "Pre-Fill" the PDS grease cavity prior to installing the AFT seal.
AFT seal installs in the Non-Conventional direction!


I did say the motor was a 4.3 due to that's what the guy at the Marina told we when I was trying to find exhaust parts.
Steer clear of this guy!

Thanks for all the help.
You are welcome.

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1984 Contessa exhaust boot & possible water leak 09 Jun 2017 20:08 #23

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I did forget to mention the port side exhaust pipe is a lot darker & gets hotter than the starboard. Is this something to be concerned with? It is darker grey opposed to white on the starboard side pipe.

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1984 Contessa exhaust boot & possible water leak 10 Jun 2017 12:18 #24

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Domenico wrote: I did forget to mention the port side exhaust pipe is a lot darker & gets hotter than the starboard.
Are you speaking of the exhaust Y-pipe?

Is this something to be concerned with? It is darker grey opposed to white on the starboard side pipe.
If discoloration is occuring....... Yes!

You most likely have an un-even flow of "spent" seawater. I would pull the system apart and examine each aspect of it.
Suspect areas:
.... manifold to elbow seawater transfer ports ..... these may be clogged up with rust scale (warm engine prior to cracking bolts loose).
.... elbow-to-Y-pipe 95mm rubber couplers are clamped over the top of the elbow's scallopped areas (very common to see this)
.... if RWC, one of the two seawater outlets in the T-Stat housing may be restricted with rust scale.
.... of the two manifold/elbow seawater supply hoses, one of them may be undergoing interior delamination.

What ever you do...... get this corrected ASAP.


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1984 Contessa exhaust boot & possible water leak 12 Jun 2017 12:25 #25

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Yes the exhaust Y pipe. Right behind the elbow off the exhaust hose. It's difficult to tell if the discoloration is from where the exhaust hose had been leaking. Going to be tearing things apart when the rain stops.
Thanks for the continued help.
Dale

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