Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

[craze1cars]

I'm doing this little project, replacing my Volvo riser gaskets with the new updated version:
http://forums.iboats.com/showthread.php?t=381272

Got the kit, read the instructions. All looks pretty simple/common sense. I have it torn apart, condition all looks similar to the pics shown in this thread...not excessively rusty. I chased all the threads with tap & die and cleaned 'em up pretty & smooth per instructions. Ready to re-assemble.

Just one question:

Volvo instructions recommend using a "spray-on gasket remover" to get the old gaskets of of the surfaces before block sanding with 80 grit. I don't have any "spray-on gasket remover."

Sooooo, tomorrow I planned to run to local auto parts store and see what I find. Before I go do that, can anyone recommend a specific product? One to avoid? An alternate recommendation INSTEAD of buying the spray-on stuff? It's hard for me to tell exactly what type of gasket is in there now...but it's definitely not the same as the new style. So I assume it is the original from 1999 assembly. It looks rather thin, silver-looking, it's on both surfaces, and it's stuck pretty good.

Volvo instructions recommend against mechanical scraping to avoid damaging surfaces.

Thank you in advance!!

 

[Don S]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

The reason for the spay on gasket remover is to prevent damage to the gasket surface. Lots of people tend to use sanding discs which round over the surfaces, or sharp chisels that gouge the metal. Then the new gaskets will not seal.
Auto parts stores sell the spray gasket remover.

 

[craze1cars]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

I understand completely. Just verifying there wasn't something already in my workshop that might be suggested or equally effective.

To the parts store I shall go...

Thank you for the quick and helpful response.

 

[wifisher]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Razor blade is the easiest way. Spray on gasket remover makes a mess and doesn't really do a good job. You can get a handle for a single edge razor for 2 maybe 3 dollars. Only reason for spray on remover is that a lot of people can't tell the difference between gasket and metal. Thus the manufacturer says not to scrape at all.

 

[fat fanny]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Just make sure when U re-install the new gasket to coat it with vasoline and or grease. This will mkae removal allot easier I have had very good luck with vasoline. And as said above both the reover and razor work great just got to be carefull with the razor!

 

[Don S]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Just make sure when U re-install the new gasket to coat it with vasoline and or grease.

DO NOT put anything on the new gaskets. They are not the same as Mercruiser, they are a metal shim gasket.
Follow the directions that came with the gaskets and you will not have any problems.

 

[wifisher]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

+1 to Don

 

[Tail_Gunner]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

I have always used this type of wire cupped brush...for yrs. It will not remove all of the gasket there is usually some very stubborn remenants that need extra care. But it will clean and polish the metal and give you a very good ideal of how clean and smooth your surface area is.

View attachment 86095

 

[craze1cars]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

I fully realize this Volvo gasket setup is far different from the Mercruiser's. And I realize that most do not seem to realize this.

And I have read and will follow the instructions to the letter...

Extreme care cleaning off gasket, no more than 0.1 mm deviation in the gasket surface, machine the parts if necessary, apply dry with NO sealer or lubricant of any type, and torque EXACTLY to specifications in a cross pattern.

I appreciate the info and know what I need to do, even if others may not...

Thanks again Don.

 

[Bondo]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Extreme care cleaning off gasket, no more than 0.1 mm deviation in the gasket surface, machine the parts if necessary, apply dry with NO sealer or lubricant of any type, and torque EXACTLY to specifications in a cross pattern.

Ayuh,.... Whenever possible, I use a flat file to clean up the surfaces of manifolds, 'n risers....
I find I'm less likely to cause divets, or imperfections, compared to using rotary tools...

 

[rickryder]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

I have always used the 3M discs to remove gasket material. They are available at the auto store and are about 2 1/2" in dia. looks like a scotch brite pad....just don't press hard on aluminum surfaces.

 

[Don S]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

I have always used the 3M discs to remove gasket material. They are available at the auto store and are about 2 1/2" in dia. looks like a scotch brite pad....just don't press hard on aluminum surfaces.

That is the EXACT tool you DO NOT want to use, and exactly what Volvo had in mind when they wrote those instructions. It will round the edges over.

 

[kwoolard]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Roloc Bristle Disc

I've used this without any problem on head surfaces, cleaning piston tops and gasket mating surfaces. For the exhaust/riser joint I do what Bondo does, run a block file over the surface after cleaning to knock down the high spots.

 

[Don S]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Roloc Bristle Disc

I've used this without any problem on head surfaces, cleaning piston tops and gasket mating surfaces. For the exhaust/riser joint I do what Bondo does, run a block file over the surface after cleaning to knock down the high spots.

Another one. DO NOT use any type of rotary tools for cleaning the surfaces on the risers and manifolds on the 94 and newer engines that use the metal shim gasket, they will roll the surfaces over and you will get leaks.

 

[Tail_Gunner]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Umm Even soft wired cup's...

 

[Fishermark]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Ayuh,.... Whenever possible, I use a flat file to clean up the surfaces of manifolds, 'n risers....

That's exactly what I would recommend. Since we have a few pics already... here's what I use:

 

[Don S]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

I give up, use what ever you want to use, if it leaks water and you loose your engine, don't blame Volvo or me when you follow DIYers advise over the manufacturers.
No other manufacturer uses these kinds of gaskets, so do whatever you guys want with your own engines, but don't waste someone else's.

 

[Bondo]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

Ayuh,.... Don't dispair Don,....

We could be talkin' 'bout Oil,....

Or Bellows adhesive....

 

[dockwrecker]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

All you can do some days is try, huh Don...:facepalm::facepalm::facepalm:

 

[muc]

Re: Best way to remove gasket material from riser/manifold joint 99 Volvo 5.0 GL

There are many ways to get most jobs done.
The DYI guys can sometimes get by not following recommended practices.
The pros (we get paid to do it right the first time) have found that following most of recommendations most of the time helps us get it right the first time.
This is one of those simple jobs that can come back to bite you.

And a FYI, Volvo changed how they want these gaskets installed in April 2010.
They came out with service bulletin 25-1-16
They now want a coat of heat resistant copper based gasket compound on the mating surfaces of both the manifold and riser. They even go so far as to recommend a couple of brands.

Will most people get by putting them on dry? We did until the service bulletin came out. But the truth is that manufactures don't issue service bulletins for no reason (they cost money) so I am pretty sure they were having issues some where in the world. So we now own a bottle of K&W Copper Coat.