How to Remove a Volvo Penta 3.0 Exhaust Manifold

A Volvo Penta 3.0 marine engine requires periodic inspection for many things. One thing you shouldn't overlook is a check for corrosion or blockage in the exhaust manifold and riser. A Penta exhaust manifold is made of a thin, cast-iron water jacket covering all of the manifold's exhaust chambers. One part of inspecting the joint for corrosion or blockage is replacement of the manifold gasket. If this gasket is damaged or has deteriorated, water leaks into the Penta marine engine, and exhaust gases leak out into your boat.

Things You'll Need

  • 5/16-inch socket
  • Ratchet
  • Phillips screwdriver
  • 10 mm socket
  • Ratchet
  • Plastic scraper
  • Gasket sealing compound
  • Gasket
  • Foot-pound torque wrench
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Instructions

    • 1

      Remove the cable from the boat-battery's negative post with a 5/16-inch socket and ratchet. Loosen the four hose clamps holding the exhaust hose to the riser using a Phillips screwdriver. Push the clamps away from the riser and back onto the hose. Push the exhaust hose off the riser, then push it down as far as you can.

    • 2

      Remove the four riser retaining bolts that hold the riser to the manifold using a 10 mm socket and ratchet.

    • 3

      Remove the manifold gasket from the manifold and scrape any gasket material remaining from the mating surfaces using a plastic scraper.

    Installing the Gasket

    • 4

      Apply gasket sealing compound to the new gasket. Insert the riser retaining bolts through the bores on the riser. Install the gasket on the riser so the retaining bolts fit through the bolt holes on the gasket.

    • 5

      Install the riser to the manifold. Tighten the retaining bolts by hand at first, then tighten to 27 foot-pounds using a foot-pound torque wrench.

    • 6

      Push the exhaust hose back onto the riser and securely tighten the clamps. Replace the battery cable.