Exhaust Collectors

Exhaust System
Section 7C - Exhaust Collectors
Table of Contents
Component Replacement.................................................. 7C-2 Preferred Exhaust System.................................................7C-4
Through‑Propeller Exhaust................................................7C-2 Magnum Bravo Model Exhaust Recommendation............ 7C-4
Water Shutter Replacement—Sterndrive Models.......7C-2 Exhaust Pipe Kit ............................................................... 7C-4
Through‑Transom Exhaust ............................................... 7C-3 Exhaust Tube Installation.................................................. 7C-5
Water Shutter Replacement—Through Transom Exhaust Resonator—Inboard Models ...............................7C-6
Models.................................................................... 7C-3

7
C

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Component Replacement
To replace any components in the exhaust system, adhere to the following:
• All mating surfaces must be clean.
• The O‑ring must remain in the groove to properly seal the joints to prevent leakage.
• Tighten all clamps securely.

a a - Mating surface
b - O‑ring

6638

Through‑Propeller Exhaust
1. Install the exhaust pipe assembly using the 4 screws and lockwashers. Torque the screws.

a - Exhaust pipe
b - Bolts and lockwashers (4)

b
a
8499

Description Nm lb. in. lb. ft.

Exhaust pipe screw 34 25

Water Shutter Replacement—Sterndrive Models

IMPORTANT: All exhaust connections, including those at the exhaust elbow, must be secured with 2 hose clamps. ABYC
standards also specify the use of stainless steel clamps with a minimum 13 mm (1/2 in.) band width. Do not use spring tension
clamps.
1. Remove and retain the intermediate exhaust pipe from the Y pipe.
2. Remove and discard the the water shutter and grommets from the Y pipe.

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3. Install the water shutter into the Y pipe. Ensure that the water shutter is seated into the rubber grommets.

a - Water shutter
a b - Rubber grommet

18483

4. Install the intermediate exhaust pipe onto the Y pipe and secure with hose clamps. Torque the hose clamps.

c
c

a b

18530

Description Nm lb. in. lb. ft.

Hose clamp (exhaust tube) 4 35

Through‑Transom Exhaust
IMPORTANT: A block off plate must be installed when using through the transom exhaust or below swim platform kits.

a - Block off plate

b - Bolts (4)

b
a

8404

Water Shutter Replacement—Through Transom Models

1. Remove the clamp securing the external cover (flapper) to the exhaust flange.
2. Remove the external cover (flapper).

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3. Remove the internal water shutter.

4. Install the new shutter. Tighten the screws and nuts securely.
5. Reinstall the water shutter in the exhaust flange to the transom exhaust.
6. Reinstall the external flapper. Tighten the clamp securely.

c
e
g
e
g

b h f
a

d 24407

Transom exhaust kit

a - Screw and nut (2)
b - Support member
c - Water shutter
d - Gasket
e - Exhaust flange
f - Bolts, washers and nuts (3)
g - Clamp
h - Cover (flapper)

Preferred Exhaust System

Most Mercury MerCruiser sterndrive engines were developed and tested for the Y‑pipe or through the propeller exhaust
systems. The only exceptions to this are the 8.2 models. However, by using the Y‑pipe system, you limit the potential for water
intrusion due to the exhaust system design.

Magnum Bravo Model Exhaust Recommendation

Use through‑the‑transom exhaust for maximum performance from the Magnum Bravo Models. Install a block‑off plate and
remove the exhaust bellows on the transom assembly. This is necessary to avoid creating a vacuum at the exhaust outlet in the
propeller at higher boat speeds. This vacuum could degrade propeller performance on some boats.

Exhaust Pipe Kit

If noise regulations do not allow the use of through‑the‑transom exhaust, an Exhaust Pipe Kit (807130A21) and the specified
intermediate exhaust elbow riser kit must be installed for through‑the‑prop exhaust. This kit also contains an exhaust tube that
is used in place of the exhaust bellows.

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IMPORTANT: To comply with the EU (European Union) Noise Emission Standard under Mercury's EU Noise Certification, the
8.2 sterndrive engines must have installed and use the exhaust pipe kit (807130A21) with a specified intermediate exhaust
elbow riser kit. Installation and use of any other exhaust components will require individual certification of the installation by the
governing authority.

24338

Exhaust pipe kit and intermediate exhaust elbow riser kit

Description Part Number

Intermediate exhaust elbow riser kit 50 mm (2 in.) 879288A13
Intermediate exhaust elbow riser kit 101 mm (4 in.) 879288A14
Intermediate exhaust elbow riser kit 152 mm (6 in.) 879288A15
Intermediate exhaust elbow riser kit 203 mm (8 in.) 879288A16

Exhaust Tube Installation

NOTE: Installing the exhaust tube will increase exhaust noise.
IMPORTANT: Remove the exhaust bellows and install an exhaust tube on the transom assembly when:
• The 8.2 engine package is equipped with a Bravo sterndrive and through‑the‑propeller exhaust.
• The exhaust system can be switched to either through‑the‑propeller or through‑the‑transom exhaust.
1. Remove and discard the clamps and exhaust bellows from the gimbal housing.

a - Exhaust bellows
b - Clamps
b

a
20130
IMPORTANT: Failure to install the grounding clip may lead to corrosion of the exhaust tube, damaging it. Always install the
grounding clip.
2. Install the grounding clip on the exhaust tube.

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NOTE: Bellows adhesive is not used when installing an exhaust tube
3. Position the tube so that the "SIDE" markings on the tube are facing the right and left sides.
4. Install the clamp.
5. Tighten the clamp securely.

e a- Exhaust tube
b- Clamp
c- "SIDE" marking
d- Exhaust tube
d e- Grounding clip

c
b
a 20131

Exhaust Resonator—Inboard Models

IMPORTANT: Exhaust resonators can be used on all models with through the transom exhaust. The exhaust resonators kit
86022A1 is purchased separately for each engine.

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• The exhaust resonator is positioned with the inside flat surface at the preferred distance of 432 mm (17 in.) from the front
edge of the exhaust hose but no closer than 51 mm (2 in.) to the exhaust outlet. The 432 mm (17 in.) dimension can be
reduced, if necessary, to a MINIMUM of 330 mm (13 in.). This dimension must be the same on both exhaust outlets.

c c
a b a b a
a
e e
d e d

g
g

f f 8232

a - Exhaust resonator
b - Exhaust hose
b c c - Dimension to inside flat
surface of resonator
approximately 432 mm
(17 in.)
c d - No less than 51 mm
a b a (2 in.) between collector
e and resonator
e f e - Clamp ‑ positioned
d around center of
resonator
f - Exhaust muffler
g 8231 g - Collector

Exhaust system tuning can be affected by various factors that are beyond the control of Mercury MerCruiser. Following are
several factors that can affect exhaust system tuning:
• Type and configuration of exhaust outlet.
• Length of exhaust hose.
• Amount of back‑pressure in exhaust system. Refer to the appropriate Mercury MerCruiser Product Applications
Manual.

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Notes:

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