826277T04 Mercury CHAP, Long - Port

Note: The illustrations were taken after the engine enclosure was removed for photographic purposes. If necessary, remove the engine enclosure in order to ease removal of the muffler on the right side of the engine. Refer to Disassembly and Assembly, "Enclosure (Engine and Pumps) - Remove and Install".
Allow the engine and the muffler to cool down before performing this procedure. Severe burns can occur from contact with a hot engine or a hot muffler.
Note: Use this procedure for either muffler.
Loosen the clamp and remove the exhaust extension from the top of the muffler.
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Attach a suitable lifting device to exhaust shield (2). Remove seven bolts (1) that secure exhaust shield (2) to the muffler. Use a hoist to remove exhaust shield (2). Exhaust shield (2) weighs approximately 25 kg (55 lb).
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Loosen clamp (3) that secures dust ejector hose (4) at the bottom of muffler (5). Remove dust ejector hose (4) from muffler (5) .Note: The dust ejector hose leads to the precleaner.
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Remove clamp (6) that secures muffler (5) to the exhaust outlet at the turbocharger.
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Attach a suitable lifting device to muffler (5). Remove four bolts (7) and washers that secure muffler (5) to mounting bracket (8). Use a hoist to remove muffler (5). Muffler (5) weighs approximately 47 kg (104 lb).Note: One of the bolts also secures the muffler brace.Installation Procedure
Note: Use this procedure for either muffler.
Illustration 5 g00780024
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Use a hoist to position muffler (5) on mounting bracket (8). Partially install one bolt (7). Muffler (5) weighs approximately 47 kg (104 lb).
Illustration 7 g00780022
Align muffler (5) with the exhaust outlet at the turbocharger. Install clamp (6) at the connection between muffler (5) and the exhaust outlet at the turbocharger. Do not tighten the clamp to the final torque.Note: Make sure that clamp (6) is completely around the flange of muffler (5) and the flange of the exhaust outlet.
Illustration 8 g00780026
Install the three remaining bolts (7) and washers that secure muffler (5) to mounting bracket (8). Tighten four bolts (7) to a torque of 100 20 N m (74 15 lb ft). Remove the hoist from muffler (5) .Note: If necessary, loosen the bolts that secure mounting bracket (8) in order to align bolts (7) with the muffler. Tighten the bolts that secure mounting bracket (8) after you install bolts (7), washers, and nuts.
Illustration 9 g00780022
Tighten clamp (6) around the flange of muffler (5) and the flange of the exhaust outlet.Note: Make sure that the exhaust coupling at the turbocharger is able to rotate. This will ensure that the muffler is not causing the exhaust coupling to bind.
Illustration 10 g00780020
Install dust ejector hose (4) on muffler (5). Tighten clamp (3) that secures dust ejector hose (4) at the bottom of muffler (5).
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Use a hoist to position exhaust shield (2) on muffler (5). Use seven bolts (1) to secure exhaust shield (2) to muffler (5). Exhaust shield (2) weighs approximately 25 kg (55 lb).
Install the exhaust extension on the top of the muffler.Note: If the engine enclosure was removed in order to ease assembly of the muffler, install the engin