71777 Mercruiser VALVE, EXHAUST (STANDARD)

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Never-Seez Marine Grade - Start By:
Remove the exhaust manifold shields.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01315551
Disconnect the thermocouples from the segments of the exhaust manifold that are being removed.
Remove adapters (1), if necessary.
Loosen the bolts that mount the exhaust manifold to the cylinder head from the segment of the exhaust manifold that is on the end. Loosen bolts (6) that mount the segment of the exhaust manifold that is on the end to bellows (5). Loosen bolts (4) that mount the bellows on the end to the adjacent exhaust manifold.
Repeat Step 1 through Step 3 for the remaining segments of exhaust manifold (3). Move toward the turbocharger when you are loosening all of the remaining bolts.
Return to the segment of the exhaust manifold that is on the end. Attach a suitable lifting device to the segment of the exhaust manifold. The weight of each segment of the exhaust manifold is approximately 25 kg (55 lb).
Remove the bolts that mount the exhaust manifold to the cylinder head from the segment of the exhaust manifold that is on the end. Remove bolts (6) that mount the segment of the exhaust manifold that is on the end to bellows (5). Remove the segment of the exhaust manifold. Remove the gasket. Remove bolts (4) that mount the bellows on the end to the adjacent exhaust manifold. Remove the bellows.
Repeat Step 5 and Step 6 for the remaining segments of exhaust manifold (3). Move toward the turbocharger when you are removing all of the remaining bolts. Brackets (2) will come apart as the bolts for the exhaust manifold and the bolts for the bellows are removed. Installation Procedure
Do not preassemble the exhaust system before installation of the engine. Damage to the bellows could result.
Apply Tooling (A) to the threads of the bolts of the exhaust manifold, the washers, the bolts of the bellows, the plugs, and the adapters before installation.
Illustration 2 g01315551
Attach a suitable lifting device to a segment of the exhaust manifold. The weight of each segment of the exhaust manifold is approximately 25 kg (55 lb). Position the gasket and the exhaust manifold on the cylinder head. Install the bolts that mount the exhaust manifold to the cylinder head. Tighten the bolts finger tight. Note: Do not tighten these bolts to the torque specification at this time.
Repeat Step 2 for all segments of exhaust manifold (3).
Install bellows (5), bolts (6), and bolts (4) on the exhaust manifold. Tighten the bolts finger tight.
Install brackets (2) on the exhaust manifold.
Tighten the bolts that mount the exhaust manifold to the cylinder head to a torque of 120 20 N m (86 15 lb ft).
Tighten bolts (4) and bolts (6) to a torque of 55 10 N m (41 7 lb ft). Ensure that the bolts for brackets (2) are tightened.
If adapters (1) have been removed, tighten adapters (1) to a torque of 200 25 N m (150 20 lb ft). End By:
Install the exhaust manifold shields.