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Exhaust System: Section 7B - Models Without Emissions Control
Exhaust System: Section 7B - Models Without Emissions Control
Exhaust System: Section 7B - Models Without Emissions Control
Exhaust System
Section 7B - Models Without Emissions Control
Table of Contents
Exhaust System................................................................. 7B-2 Loading the Boat (Boats with a Capacity Plate)......... 7B-4
Exhaust System Caution............................................ 7B-2 Loading the Boat (Boats Without a Capacity Plate)
Exhaust System Connections.....................................7B-2 ................................................................................ 7B-6
Exhaust Emissions Sampling..................................... 7B-2 Clear Hose Measurement Method..............................7B-8
Through‑Hull Exhaust Fittings.................................... 7B-2 Clear Hose Measurement Method From Seacock or
Reference Note..................................................................7B-3 Muffler Drain............................................................7B-9
Measuring Exhaust Elbow Height...................................... 7B-3 Manifold and Elbow..........................................................7B-11
General Information.................................................... 7B-3 Exploded View.......................................................... 7B-11
Boat Requirements..................................................... 7B-4 Replacing the Manifold............................................. 7B-12
Loading Requirements................................................7B-4 Inboard Applications................................................. 7B-16
7
B
Exhaust System
Exhaust System Caution
NOTICE
Improperly designing, installing, or modifying the engine’s exhaust system can introduce seawater or water from
condensation into the combustion chambers, damaging the engine. The installing dealer or boat builder is responsible for
proper installation of the exhaust system as explained in the installation instructions for the product. Engine damage resulting
from water ingestion is not covered by the product warranty, unless the damage is the result of a defective part supplied by
the engine manufacturer.
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Access area for exhaust gas sampling—Non-Emission Controlled 8.2 MAG and 8.2 MAG H.O. Models
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Reference Note
Refer to the appropriate Mercury MerCruiser Product Applications Manual for more in depth diagnosis and set up
installation of the exhaust systems.
If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate exhaust riser.
Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers.
The maximum exhaust riser height is specified in the table below.
a - Inclinometer
c
b - Exhaust hose or tube
c - Length of exhaust hose or tube
a
b
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Boat Requirements
IMPORTANT: Consider the following requirements before performing the exhaust elbow waterline height measurement. No
prototype hulls or light layup hulls should be considered. Any measurement performed on non‑production boats, prototype
hulls, or light layup hulls could be inaccurate and could result in product damage.
• All boats that display a CE certification capacity plate must use the maximum capacity as stated on the CE
certification capacity plate to perform the exhaust elbow waterline measurement.
• All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as stated on the
USCG capacity plate to perform the exhaust elbow waterline measurement.
• For boats that do not have a capacity plate, the maximum capacity load is the number of persons that can sit on
designated seating plus cargo excluding cabin space.
• Measurements used for official Mercury MerCruiser audit at the OEM boat builder must be performed on current production
boats. No prototype hulls or light layup hulls will be considered for official audit purposes.
• Measurements used for official Mercury MerCruiser audit at OEM boat builders must use the CE certification maximum
load for any boat model that will be sold outside of the United States.
Loading Requirements
1. Fill the fuel tanks, fresh water tanks or holding tanks, ballast tanks, and heater tanks to simulate fully loaded condition.
2. Weights can be used to simulate these load conditions if desired. Place weights in the corresponding area for which the
load is being replaced. Refer to the following conversions.
• 1 U.S. gallon of water = 8.3 lb
• 1 liter of water = 1 kg
• 1 U.S. gallon of gasoline = 6 lb
• 1 liter of gasoline = 0.72 kg
3. For the purpose of MerCruiser waterline height measurements:
• One person is equivalent to 74.84 kg (165 lb)
• Cargo per person is equivalent to 11.34 kg (25 lb)
4. Add weight for any additional boat options: extra battery, battery charger, tower, arch, generator, ballast tanks, ballast
sacks, television, carpet, anchor, stereo/entertainment equipment, washer/dryer, safe, etc.
5. If a swim platform is an option, the swim platform must be installed for the waterline height measurement. Use the following
guide to determine the correct swim platform load:
a. Boats less than 8.84 m (29 ft) long, not including boats that are 8.84 m (29 ft) long, must add the maximum rated
swim platform weight capacity to the swim platform.
b. Boats less than 8.84 m (29 ft) long, not including boats that are 8.84 m (29 ft) long that do not have a maximum rated
swim platform weight capacity, must add181.45 kg (400 lb) to the swim platform .
c. Boats 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, must add the maximum rated swim platform weight
capacity to the swim platform.
d. Boats 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, that do not have a maximum rated swim platform
weight capacity must add 226.80 kg (500 lb) to the swim platform.
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IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat.
5. Using the totals in this example, load four 165‑lb. persons and one 40‑lb. person onto boat seating with 400 lb. on the swim
platform.
• 400 lb. + 165 lb. = 565 lb.
• 565 lb. + 165 lb. = 730 lb.
• 730 lb. + 165 lb. = 895 lb.
• 895 lb. + 165 lb. = 1060 lb.
• 1060 lb. + 40 lb. = 1100 lb.
d e
b
a
c
f
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Example
NOTE: The following example is provided as a reference.
This example uses a boat that is 8.84 m (29 ft.) long and greater than 8.84 m (29 ft.) long, that does not have a maximum rated
swim platform weight capacity, and must add 226.80 Kg (500 lb.) to the swim platform .
IMPORTANT: The Designated Seating Diagram following illustrates the number of passengers that can sit on designated
seating excluding cabin space.
6 9
2
4 7
1
5 8
3
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g
c i
a e j
b h
f
d
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b a - Clear hose
b - Fitting
b c c - Unrestricted opening
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b a - Waterline
b - Top of exhaust elbow
c - Waterline to top of exhaust elbow
measurement
d d - Clear hose
a e - Weight
c
d
e
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b
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IMPORTANT: Horizontal waterlift mufflers are permitted for use only if the bottom of the muffler is below the crankshaft
centerline.
b 44883
a- Exhaust elbow
b- Elbow gasket
a c- Riser
d- Turbulator plate and gasket
elbow flange
b e - Fittings
f - Exhaust manifold
c a
d d
e
f e f
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b
a
e
b f
c c
d h
g
d
j
j
c i
b 48677
c
b i
a- Exhaust elbow
b- L‑bracket bolt
c- Hose and clamps
d- Exhaust manifold
e- Nut and washer (4)
f- Stud (4)
g- Cap screw (4)
h- Exhaust riser
i- Spark plug wire (4)
j- Bolt (8)
Installation
1. If replacing the manifold, remove the exhaust manifold coolant temperature (EMCT) sensor, L‑bracket, and the water drain
fitting from the manifold. Note the orientation of the water drain fitting and the L‑bracket, and install them in the new
manifold.
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b. Hand‑start the EMCT sensor in the manifold.
c. Tighten the sensor to specification and position the connector temporarily out of the way.
a a- L‑bracket
c d
b- L‑bracket screw
b c- EMCT sensor
d- EMCT sensor connector
(temporarily out of the way)
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g. If discarding the manifold on models with a six‑inch riser, remove and retain the studs from the old exhaust manifold.
2. Hand‑tighten two alignment pins (if available) into the manifold location holes matching the gasket shown.
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3. Place the new exhaust manifold gasket on the cylinder head. Allow the alignment pins to hold the gasket in place.
4. Attach the new exhaust manifold to the head using hex head cap screws.
NOTE: Install the short screws in the recessed location holes and the long screws in the raised location holes.
5. Remove the alignment pins once you have secured the manifold with at least two screws.
6. Tighten the screws to specification in the sequence shown below.
8 3 7 1
2
6 4 5 48939
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a. Install the studs in the corresponding holes in the exhaust manifold. Tighten the studs until the threads are bottomed
out in the manifold.
a - Studs
b - Turbulator gasket
a
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b. Install the riser on the turbulator gasket on the manifold.
c. Install the gasket on the riser.
d. Place the exhaust elbow on the gasket on the riser.
e. Install a washer and nut on each stud.
f. Tighten the nuts to specification.
e
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Inboard Applications
An adapter fitting is supplied for inboard applications that use a shaft log cooler hose. Remove the appropriate plug from the
end of the manifold. Install the adapter and install the shaft log fitting from the original manifold system.
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