Mercruiser Sterndrive Cooling Parts

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Cooling How-To's

Tips on installing exhaust manifolds and riser

Tips on Installing Exhaust Manifolds and Risers on Your Boat

Regular installation and maintenance are required on all components of a boat, and such is the case for exhaust manifolds, risers, elbows, and all ... read more other related portions. The following guide will help you safely and accurately perform this process, and will familiarize you with the different tools and accessories that should be used.

Preparation

Preparation goes hand in hand with cleaning out your application and stripping down anything that might be worn away. Following the suggestions below step-by-step will ensure that your engine and exhaust system will be better protected, as well as make it last much longer.
  1. Remove the paint off of the surfaces of the gasket with the help of a fine blade and thinner. Work with patience at a steady pace to avoid scuffing up the surfaces. Blow any residual debris out of the passages and jackets by using compressed air. Do not use anything too powerful or heated.
  2. Check your new replacement manifolds and risers for any sign of casting pieces within their water jackets. It is no cause for concern, but rather a part of the process. You can or should blow these out with compressed air as well before installation.
  3. Before proceeding with anything else, make sure your gasket surfaces are clean and smooth. Avoid getting any excess debris or casting pieces lodged into the setup.
  4. Some parts may be reused if they are in near-pristine condition, such as bolts, fittings, etc. Anything with signs of rust or any form of deterioration should not be reused.
  5. Gaskets should never be recycled, but always replaced with new gaskets.
Installation

Now that you have cleaned out your exhaust system, it is time perform the actual installation. Wind down all of your bolts/nuts to the right torque setting. Then imitate the following steps:
  1. Do not tighten the bolts more than necessary because it could cause the parts to become stripped. Stripping these parts could also void the warranty.
  2. Do NOT use any sealant to help install the manifold-to-head gaskets. They should be installed completely dry.
  3. The riser and elbow gaskets may be put in with a non-hardening sealant, especially if they are thinner gaskets. However, it is not necessarily required for thicker gaskets.
  4. Unless otherwise advised, do not attempt to apply anti-seize or any other kind of lubricant on bolt/stud threads.
  5. Some models will permit the option to upgrade to stainless steel bolts, while others do not. Talk with a technician before making any changes.
  6. Use a thread locking compound on whichever threads will rest in the casting. Using a thread locking compound will allow the nut to be screwed on and off with minimal adjustments.
  7. Refer to a local mechanic or your owner's manual for specifics on torque settings during installation. Pace yourself when you torque.
  8. Reset your torque shortly/immediately after your first test.
  9. Do not tighten the pipe fittings or plugs too much to avoid stripping.
With your new parts/system assembled, double-check all hose clamps and hoses to ensure that they are correctly installed and tightened. Analyze the entire engine and verify that there is no residue, and do not leave any tools laying around.

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