Major exhaust leaks turbo/manifold 6CTA 450

[David R]

So this is my first season with a new boat.
450 diamonds in a 41 formula PC
950 hours 2600max RPM’s intercoolers done 2 years ago. A cruising speed’s motors are not visibly smoky but leave plenty a soot down the side of the boat

I noticed a small exhaust leak. After examining the exhaust leak further I noticed two of the bolts on the turbo downpipe were broken. I also noticed a small amount of soot on every exhaust port on the exhaust manifold. I wound up running it another 15 hours and when I got back half the motor is covered in soot.

I have on order new turbo exhaust gasket/bolts. Turbo to manifold gasket. Red RTV.

I’m looking for advice and any suggestions on how to get these bolts out of the turbo and also where I could buy a exhaust manifold gasket…

Thanks

Dave

Topic

[David R]

that would be correct

[J Dragon]

That pic looks like inside of his exhaust elbow where it mates to the turbo

[Tony Athens]

Not exactly sure what I am looking at, but for sure it’s on a 100% saltwater diet..

You have some serious installation related issues that need to be addressed if this is an indication of what is going on in your engine room.

No one can help you remotely until you can take pictures showing everything from all angles and all perspectives, all clear and in focus.. Close-ups are great for somethings, but we need pictures showing all from 3- 6 ft away…………………….

[David R]

I’m trying Tony sorry for the delay I appreciate the help but unfortunately I don’t have a computer to upload them correctly at the moment.

[Tony Athens]

Still waiting for the pics you sent me to be sent in a “Look-a-ble” format—————-I.E.–hi-res .JPG attachments.. Not embedded in the email as you did..

The current pic here.. From what I see——-Although this was a typical dry/factory assembly, you did not have a issue with this connection..

[David R]

This stinks

[David R]

Thank you emailing them to you in full res

[Tony Athens]

Can you send me all the pics ( and more if you like) direct to me in hi-res as .jpg attachments.. That will save me a lot of time to come up with a plan to move fwd..

[email protected]

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David R

[Rob Schepis]

Raymond W Smith wrote:

Is there a 1/2″ SS Spacer there also????

No spacer, just the OEM wet elbow mated to the turbo. Overall pics show good engine room height to re-do this safely with a tall dry riser.

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David R

[David R]

Yes all the pictures I uploaded where taken after our last trip.

[Tony Athens]

Question——–Are the pics you just posted all from the exact same time? 100% current after the 15 hour trip or ??…………………………….Realize, I have to relay on what you post..

1 user thanked author for this post.

David R

[David R]

Tony first off thanks so much for getting back to me I’ve been lurking around these forms for a while fortunately I haven’t needed them to now.

1.) trust me I understand this is a major exhaust leak that was the title of my post.

You are correct this didn’t just happen before I took our last excursion there was a 15 hour ride I did a full inspection prior I noticed a small amount of soot around the bottom of the turbo and exhaust manifold at this point this is the first time I noticed it was leaking. You are correct this didn’t just happen before I took our last excursion that was a 15 hour ride I did a full inspection prior I noticed a small amount of salt around the bottom of the turbo and exhaust manifold at this point this is the first time I noticed it was leaking After a 15 hour ride it got about 100 times worse.

3.)) I had a certified marine inspector look I did not have an engine mechanic come.

4.) that’s what I’m fearing

5.) yes the exhaust riser or if you call it that looks like a really stupid design.

6.)I took a bunch more pictures hopefully this helps I just want to get this boat squared away.

[Tony Athens]

I do not like what I see at all and you need to heed this warning.

1)—This is not a small exhaust leak–I would consider this MAJOR for this particular engine

2)–This did not just happen– this has been going on for some time and a prudent, proper & typical engine room inspection with “open eyes” before each trip would have picked this up a long time ago..

3) –Who inspected this engine room before you bought it? Got some pictures or something from “during the purchase time frame”?

4 –This goes way deeper that some new gaskets and broken stud–That I guarantee–This engine does not have this type if issue unless there are other issues that caused it

5)–From the little I can “see” your exhaust riser /elbow/mixer is very scary and I think is a typical “doomed to failure” design.

Next–stand back 3-5 ft and take good pics of all showing everything on, and around your engine as it is.. I want to see the entire engine, exhaust aftercooler, turbo etc etc etc .

Things are not right and it all needs to be looked at by a proper set of eyes….This engine only has 950 hours? That’s way less than one season in the boats we deal with with this exact engine. Things are NOT RIGHT and 99%+, it is related to the original installation and it is now caught up with you, the present owner.

Tony

[David R]

Sounds like a plan I’m not sure if there is a spacer in there

[Raymond W Smith]

Take to a machine shop to have broken bolts removed and have all matting surfaces dressed up. Gaskets available from Seaboard Marine!!! Been through all this. Is there a 1/2″ SS Spacer there also????

[David R]

Didn’t even think of the soot getting sucked back in to the motor! Thanks

[Philip]

All that soot certainly got into your air cleaner and possibly the aftercooler air side. At two years it’s ready to be removed and cleaned again anyways unless your a fresh water flusher.

When you get the manifold off double check for anything warped before reassembly.

Phil

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David R

[David R]

Picture

Pictures of my mess

[Author]

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