Merc 3.0 water shutter replace

[Browntailer]

Need to replace the water shutter in my 2005 Merc 3.0, s/n 0w303873 (found half of it when I cracked the lower half of the drive to change the impeller). 2 dealers told me that the engine actually runs warmer than normal without it. Anyway, does anyone know how / have an easy way to get the rubber boots/ sleeves off the the pipe assembly? The parts catalog calls them simply "exhaust tubes" and the P/N is 32-9094t. They are so thick and heavy/rigid that I can't even budge them even though I got the clamps off (can't roll or fold them over). I know that after 4 summers of operating they are actually cooked to the pipe assembly, so I did separate that seal as much as possibe using WD-40 and a screwdriver to wedge in between the rubber and metal, but they are still unmovable. Do you actually have to take off the exhaust elbow to twist it out and then work your way down from there? Thanks for the help.

 

[jerryjerry05]

Re: Merc 3.0 water shutter replace

Might be easier to remove the whole manifold than just the riser.Just removing the riser and it might be hard to reseal.J

 

[Don S]

Re: Merc 3.0 water shutter replace

I would just remove the riser. If there is problems getting it to reseal, then you were about to have problems with it anyway. Just get the surface clean and flat, and you won't have problems with the OEM gasket (NOT aftermarket) and installing per the manual.

 

[Browntailer]

Re: Merc 3.0 water shutter replace

Thanks for the ideas guys. Because of this issue and the subsequent delay, I won't be able to even look at it again for about 3 weeks. I'll definitely report back then, and would appreciate more info/other ideas from anyone who may have worked this same issue on a comparible Merc engine.

 

[Browntailer]

Re: Merc 3.0 water shutter replace

RESOLVED

I didn't have to even touch the manifold. I had to find a guy who had done it before who was willing to talk to me about what he learned through trial and error. Essentially, you have to move the BOTTOM of the two thick rubber exaust tubes that hold the cast iron connector to the manifold elbow and the lower unit. The top one does not move because it is intentionally impeded by tabs on both sides. After you get it loose (more to come on that), you slide the bottom tube far enough up the cast iron connector that you can then twist the cast iron connector and both tubes off of the assembly. You will see the valve right there, inside the lower unit, and replacing it is self explanitory. I would recommend getting the rubber mounts for the shutter before you do this becuase they should probably be replaced too.

To get the boots loose initially, use liquid dish soap and water as a lubricant, same stuff you might have on your boat in a sprayer for your boots/bindings. When it dries, it allows the boots to re-bond/seal with the metals to which arey clamped. WD40 does not, and I was told that it is a fire hazzard. Work the sprayed soap down into the boot with a LONG SKINNY screwdriver shaft. There isn't any room or leverage to come at it from the bottom, so you are better off going all the way through the boot from top to bottom, and then dragging it around the edges to break the seal completely. Once you have done this, if there is enough soap in there, the boot will slide up the cast iron connector with little force. Reassembly is very easy, just keep track of your clamps. Have fun....and thanks for your help.