EXHAUST SYSTEM - Discount Marine
Contents
1. 7C 8 90 861327 1 OCTOBER 1999 SERVICE MANUAL NUMBER 24 COLLECTORS 1 Position tube so that SIDE markings on tube are facing toward the right and left sides 2 Install clamp 3 Tighten clamp securely 22184 a Exhaust Tube b Clamp c Side Marking d Exhaust Tube e Grounding Clip 72539 a Silencer Valve Assembly b Hose Clamps 90 861327 1 OCTOBER 1999 Page 7C 9 COLLECTORS SERVICE MANUAL NUMBER 23 Air Tube Routing 1 Route air tubing from air pump to silencer valve cylinders Do not route air tubing close to hot surfaces Excessive heat will damage air tubes 72775 Single Engine a Air Tube b T Fittings c Air Pump Assembly d Air Tube To Air Cylinder On Each Silencer Valve 72776 Dual Engine a Air Tube b T Fittings c Air Pump Assembly d Air Tube To Air Cylinder On Each Silencer Valve Page 7C 10 90 861327 1 OCTOBER 1999 SERVICE MANUAL NUMBER 24 COLLECTORS Maintenance 1 Air Intake Filter 32 17272 must be checked once each year If filter is clogged or partially clogged replace The filter pad is glued in and may be removed with needle nose pliers Clean surface in casting apply a single dot of Quicksilver Sound Blanket Glue to center of casting and install new filter Be careful not to coat filter or clog air intake holes with adhesive Phra Wet SJ 3 72534 Relief Valve 30 PSI 2 Ft 610 mm Ground Wire Connect To Terminal Must Be Gro2. Number 92 825407A3 92 809833 92 809824 92 86166 1 92 34227 1 92 257 11 3 92 25234 90 861327 1 OCTOBER 1999 SERVICE MANUAL NUMBER 24 COLLECTORS Bullhorn Exhaust Shutter Replacement IMPORTANT Engine does not have to be removed to change shutters 1 Loosen clamps and remove exhaust pipe elbow and exhaust hose 2 Replace water shutter 3 Reinstall pipe elbow and hose Tighten clamps securely N lt a Pin A Eg 75760 a Exhaust Flapper b Rubber Grommets 90 861327 1 OCTOBER 1999 Page 7C 3 COLLECTORS SERVICE MANUAL NUMBER 23 Component Replacement To replace any components in exhaust system the following must be adhered to e All mating surfaces must be clean e O ring must remain in groove to properly seal joints to prevent leakage e Torque all bolts to 20 25 Ib ft 27 34 Nm e Tighten all clamps securely 72736 a Mating Surface b O Ring 12737 c Exhaust Hose d Water Shutters e Bolts and Lockwashers f Exhaust Pipe Page 7C 4 90 861327 1 OCTOBER 1999 SERVICE MANUAL NUMBER 24 COLLECTORS Thru Transom Exhaust Shutter Replacement IMPORTANT A block off plate must be installed when using thru transom exhaust or below swim platform kits 22057 a Block Off Plate b Bolts 4 1 Remove exhaust hose clamps then hose 2 Chisel rivets away from both support members 27761 a Shutter Hinge b Water Shutter Opens Toward Ou
3. ANUAL NUMBER 23 Silent Choice Exhaust System If engine is equipped with thru prop exhaust a thru transom kit 4 in 102 mm two exhaust bellows and eight bellows hose clamps are required If engine is equipped with thru transom exhaust an exhaust pipe kit P N 44266A6 is required containing the exhaust pipe and necessary parts IMPORTANT When installing Silent Choice exhaust it is recommended that the exhaust bellows on the transom assembly be removed This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds This vacuum could degrade propeller performance on some boats It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install exhaust system Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine Damage caused by water in the engine will not be covered by Mercury MerCruiser Warranty unless this damage is the result of defective part s Exhaust Tube Installation 1 If required remove and discard clamps and bellows from gimbal housing 22116 2 If required install exhaust tube on gimbal housing as follows 3 Remove and discard clamps and exhaust bellows Exhaust tube clamp may corrode if grounding clip is not installed a Install grounding clip on tube NOTE Bellows adhesive is not used when installing an exhaust tube Page
4. SERVICE MANUAL NUMBER 24 COLLECTORS EXHAUST SYSTEM Section 7C Collectors Table of Contents Torque Specifications C 2 Silent Choice Exhaust System 7C 8 Lubricants Sealants Adhesives 7C 2 Exhaust Tube Installation 7C 8 Bullhorn Exhaust 7C 3 Air Tube Routing 7C 10 Shutter Replacement 7C 3 Maintenance 0008 7C 11 Component Replacement 7C 4 Exhaust Muffler Kit 7C 12 Thru Transom Exhaust 7C 5 Cleaning and Inspection 7C 13 Shutter Replacement 7C 5 Installation wie ween daca NAGANA NA 7C 14 Component Replacement 7C 6 Maintenance Instructions 7C 15 Below Swim Platform Exhaust Pipe C 90 861327 1 OCTOBER 1999 Page 7C 1 COLLECTORS Torque Specifications Fastener Location Block Off Plate Exhaust Pipe to Gimbal Housing Exhaust Pipe to T Pipe T Pipe to Gimbal Housing Upper Exhaust Pipe to Lower Exhaust Pipe Exhaust Elbow Air Pump Mount Muffler End Plate Mode Switch Hose Clamps Water Shutter Bolt Nut Lubricants Sealants Adhesives Page 7C 2 Description Quicksilver 2 4 C Marine Lubricant With Teflon Loctite 35 Loctite Primer 3M Brand Adhesive Quicksilver Perfect Seal Quicksilver Liquid Neoprene Quicksilver Sound Blanket Glue SERVICE MANUAL NUMBER 23 bn mm Nm g 20 25 27 34 Part
5. ed must be installed in order shown 72780 1 1 4 Inch Muffler Riser Installation Exhaust Manifold Exhaust Elbow Bolt 4 Each Manifold Gasket Lightly Coat Both Sides With Quicksilver Perfect Seal Riser 1 1 4 Inch 82 mm Height Restrictor Gasket Open Gasket on Later Models Refer To Note Following O hM QA T XD NOTE Later models will have an open gasket four slots instead of a restrictor gasket two slots and two holes If replacing gaskets it is acceptable to replace the old gaskets with the open gaskets Be sure that the same type of gasket is used on both manifolds Page 7C 12 90 861327 1 OCTOBER 1999 SERVICE MANUAL NUMBER 24 COLLECTORS Cleaning and Inspection 1 Disassemble muffler as shown 72782 a Removable End Plate b 4 Screws Secure End Plate c O Ring Seal d Element When Reassembling Seat Tab In Slot In Casting 2 Clean using pressurized water and inspect parts including filter element and O ring seal If required replace O ring securing in place with Quicksilver Sound Blanket Glue 3 Reassemble as shown above Tighten end plate screws securely 90 861327 1 OCTOBER 1999 Page 7C 13 COLLECTORS SERVICE MANUAL NUMBER 23 Installation 1 Install muffler as shown into exhaust hose and molded tube Fabricate muffler to tran som using 4 in I D exhaust hose cut to required length NOTE Removable end of muffler ALWAYS goes toward exhaust elbow This place
6. of O ring seal if dried out or shrunk below mating surface remove and replace Clean groove thoroughly b Glue new O ring seal in groove using Sound Blanket Glue Wipe off excess glue immediately Reinstall muffler end plate with four screws Tighten securely Reinstall muffler into tubes hoses Double clamp Tighten securely Check area around exhaust elbow and riser gaskets for leakage Replace gaskets if necessary Water must be completely drained from exhaust elbow riser during freezing temper atures or water may freeze and cause severe damage to riser 90 861327 1 OCTOBER 1999 Page 7C 15
7. s direc tion marks on muffler body casting at the upper rear corner on the port side 72783 IMPORTANT A MOLDED exhaust tube MUST be used at exhaust elbow connection to maintain positive separation of exhaust outlet and muffler inlet 72781 a Muffler b Molded Exhaust Tube Muffler To Elbow c Exhaust Hose Muffler To Thru Transom Fitting Cut To Length d Double Clamp Each Connection Not Shown On Hose C 2 Double clamp each connection Tighten each clamp securely IMPORTANT After starting engine check installation for leaks Page 7C 14 90 861327 1 OCTOBER 1999 SERVICE MANUAL NUMBER 24 COLLECTORS Maintenance Instructions Maintenance inspection is owner s responsibility and must be performed at intervals speci fied in owner s Operation and Maintenance Manual 1 2 3 Check exhaust elbow attaching nuts for adequate tightness 20 25 Ib ft 27 34 Nm Check hose clamps for adequate tightness Periodically check tubes hoses for soft spots brittleness cracks and general condition Replace as necessary As needed depending on use conditions remove mufflers then remove four screws securing forward end plate and remove end plate and element and interior of muffler Clean thoroughly at least once each year using pressurized water 72782 Removable End Plate 4 Screws Secure End Plate O Ring Seal Element When Reassembling Seat Tab In Slot In Casting 20 TO a Check condition
8. tside Of Boat c Support Member d Rivets 4 3 Install new shutter as shown in Component Replacement following Tighten screws and nut securely 4 Reinstall exhaust hose Tighten clamps securely 90 861327 1 OCTOBER 1999 Page 7C 5 COLLECTORS SERVICE MANUAL NUMBER 23 Component Replacement 72740 Transom Exhaust Kit Screw And Nut 4 Support Member Water Shutter Hinge Must Be Vertical Gasket Exhaust Flange Bolts Washers and Nuts 3 Clamp Cover Flapper gt Q AM 20 TO Page 7C 6 90 861327 1 OCTOBER 1999 SERVICE MANUAL NUMBER 24 COLLECTORS Below Swim Platform Exhaust Pipe This exhaust kit may be used on any MerCruiser installation having a 4 in 102 mm exhaust elbow 72742 a 8 Per Kit b 2 Per Kit The below swim platform exhaust pipe can be modified for specific height applications by cutting pipe at location shown 72743 a Cut Line See Notes b To Engine c lo Transom NOTE If riser kits are installed or if more vertical drop is required cut a must be made and the upper and lower sections of the pipe rejoined with a 4 in 102 mm I D exhaust hose of the required length Secure with hose clamps NOTE Prime and paint any raw cut aluminum surface IMPORTANT Each exhaust bellows must be double clamped at each connection The hose clamps are torqued to 30 40 Ib in 3 5 Nm 90 861327 1 OCTOBER 1999 Page 7C 7 COLLECTORS SERVICE M
9. unded To Engine k Air Intake Filter 2 Lubricate air cylinder to silencer pipe flapper at clevis and pin as needed with Quick silver 2 4 C Marine Lubricant a Mode Switch b Keyway Install In DOWN Position c BROWN Wire To Terminal 3 Activates Compressor d PURPLE Wire 12 Volt Connect To 12 Volt Source In Control Panel Area e GRAY Wire To Terminal 1 Activates Solenoid f Air Pump g Solenoid h Check Valve i j 72778 a Lubricate Clevis And Pin With Quicksilver 2 4 C Marine Lubricant 90 861327 1 OCTOBER 1999 Page 7C 11 COLLECTORS SERVICE MANUAL NUMBER 23 Exhaust Muffler Kit This muffler designed for use on all V 8 engines with Plus Power exhaust systems 4 in 7 degrees downward outlets requires the installation of 1 1 4 in 32 mm exhaust elbow risers which are included in the kit IMPORTANT If a thru transom exhaust kit other than the one from Mercury Marine is used the exhaust kit must be equipped with internal shutters and external flap pers It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install exhaust system Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine Damage caused by water in the engine will not be covered by Mercury MerCruiser Warranty unless this damage is the result of defective part s IMPORTANT Restrictor gaskets if equipp
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