Exhaust manifold gasket replacement

[h20king 794]

Well I guess it was my turn. The boat hit 100 hours and tic tic tic. The exhaust manifold gasket failed. Since this seems to be a common problem, I took pics and decided to do another how to thread. The job is strait foreword and does not take much time. To make things easier, I got two old manifold bolts, cut the heads off and made a grove in the center of the bolt(so a flat head screw driver can be used to install them). Start by removing the blue plug on the bottom of the manifold and drain all the water from it. Leave the plug out to avoid breaking it when removing the manifold. Next loosen all the hose clamps that are attached to the manifold. Then remove the two smaller hoses leaving the large exhaust hose in place. Spray the large exhaust hose with some lubricant and let it soak while you move foreword. Next take a 9/16" socket and break loose the four exhaust manifold bolts, removing only the two center bolts. This is where the new slotted bolts come in, insert them in the two center exhaust manifold holes. Screw them in with a flat head screw driver,they will support the weight of the manifold and allow you to slide off the manifold after removing the two last bolts. With all bolts removed slide the manifold out, pull back and its free. Set it port side up in the storage locker. Put a sheet or blanket under the head and manifold while you scrape and prep the surface this will catch most of the graphite and not make as big a mess. With the surfaces cleaned its time to reinstall remove the guide pins place a bolt through the foreword manifold hole put the gasket on the bolt and lift back in place. Let the large exhaust hose support some of the weight lift and start the first bolt.Lift the rear corner start the second bolt then its smooth sailing put in the remaining two bolts and only tighten hand tight. Next torque all the bolts to 30 foot pounds starting at the center two bolts and working your way out.Connect all the hoses tighten all the clamps put in the blue plug (Dura) Then start test and then clean up the mess your now done so sit back, pat yourself on the back for a job well done and have a cold beer....................................H

[h20king 794]

Remove the blue plug drain then remove the small upper and lower hose

[h20king 794]

remove center bolts insert new slotted bolts remove last two bolts then slide off and set port side up

[h20king 794]

you can see on the gasket and the head where the leak was

[h20king 794]

put a sheet or blanket down while you scrape and clean the surfaces then reassemble following instructions above and torque bolts to 30 foot pounds starting at the center two and working your way out

[xsummit 0]

Is there a better or udated product for this gasket leaking problem?

[h20king 794]

No but you could take your manifold and have a machine shop deck the ports so that they are perfectly true might help might not...........................................H

[xsummit 0]

No but you could take your manifold and have a machine shop deck the ports so that they are perfectly true might help might not...........................................H

Yeah, it would help if the heads were perfect too.

[Tommywalton1974 175]

I've learned from other boats that every year I replace the riser/manifold gasket and check the mating surfaces. Corrosion is common in this area. If it fails and leaks water can end up in your cylinder. If your lucky it will just hydro lock. If your piston is down and it sits all winter... Rusty rings ain't good

[acpilot 1]

Great article. Just replaced mine on my Elite Bowrider ( DD). If anyone is changing their exhaust gasket on a direct drive here is a tip: Place a rachet stap around the riser and the top of the tower. Tighten but leave leave a bit of slack. This will support the riser when you loosen the bolts and will prevent the riser from slipping and breaking a bolt. Just slide it back , clean the old gasket off, reinstall.