805268 Mercruiser SENDER

1. Disconnect inlet water line (1) and outlet line (3).2. Remove bolts (2) that hold the manifold in place.3. Fasten a hoist and remove exhaust manifold (4). Weight of the exhaust manifold is 36 kg (80 lb). The following steps are for installation of the exhaust manifolds.4. Put the gaskets and exhaust manifold (4) in position on the cylinder block.5. Put 5P3931 Anti-Seize Compound on the bolt threads and install them. Tighten bolts (2) to a torque of 43 7 N m (32 5 lb ft).6. Connect inlet water line (1) and outlet line (3).Remove & Install Exhaust Manifolds (Marine Engine With Turbocharger)
Start By:a. remove turbocharger 1. Disconnect hose (1) from the manifold assembly. 2. Fasten tooling (A) and a hoist to each end of the exhaust manifold as shown. Remove bolts (2) and bolts (4) to remove elbow (3) and the exhaust manifold as a unit from the engine. The weight of the unit is 32 kg (70 lb).3. Do Step 2 for the opposite side of the engine.4. Remove elbows (3) from the exhaust manifold. 5. Remove vent line (7). Remove two bolts (5) and manifold assembly (6) from the rear of the engine. The following steps are for installation of the exhaust manifolds.6. Put manifold assembly (6) in position and install bolts (5). Do not tighten the bolts at this time.7. Install vent tube (7).8. Put the gasket and elbow (3) in position on the exhaust manifold. Install the bolts to hold the unit together. Do not tighten the bolts at this time.9. Fasten tooling (A) and a hoist to the exhaust manifold as shown. Put the exhaust manifold and the gaskets for elbow (3) and the exhaust manifold in position. Install bolts (4) and tighten them to a torque of 43 7 N m (32 5 lb ft).10. Connect hose (1) to the exhaust manifold.11. Install bolts (2) that hold elbow (3) to the rear manifold. Do not tighten the bolts at this time.12. Repeat Steps 8 through 11 for the opposite side. 13. Tighten the exhaust manifold bolts in letter sequence as follows:a. Make sure bolts (A) are tightened to a torque of 43 7 N m (32 5 lb ft).b. Tighten bolts (B) through (D) to a torque of 1 N m (1 lb ft) finger tight.c. Tighten bolts (B) through (D) to a torque of 14 7 N m (10 5 lb ft).d. Tighten bolts (B) and (C) to a torque of 43 7 N m (32 5 lb ft).e. Tighten bolts (D) to a torque of 100 14 N m (75 10 lb ft).End By:a. install turbochargerRemove Exhaust Manifolds (Industrial Engine)
1. Remove two bolts (1) from the flanges. 2. Bend the tabs back on locks (2). 3. Remove the bolts, exhaust manifold (3) and the gasket.Install Exhaust Manifolds (Industrial Engine
1. Put the gasket and exhaust manifold (1) in position. Put 5P3931 Anti-Seize Compound on the bolt threads.2. Install locks (2) and bolts (3).3. Tighten the bolts to a torque of 43 7 N m (32 5 lb ft). The locks must be bent on a flat side of the bolt head. Bolts must be turned no more than 30° of a turn (in the direction of increased torque only) for the alignment of the locks with a flat side of the bolt head. 4. Put bolts (4) and the flange in position. Install the nuts.