864293A02 4.3L (262 CID) MANIFOLD CONVERSION Models Covered Notie Prts List Additionl Prts Needed Models Covered Seril Numer Or Yer 4.3L (262 CID) Single Piee Mnifolds 0F803800 nd Aove NOTICE After ompleting instlltion, these instrutions should e pled with the produt for the owner's future use. NOTICE This doument is written to id our delers, otuilders, nd ompny servie personnel in the proper instlltion or servie of our produts. Persons who re not fmilir with these or similr produts produed y Merury Mrine, nd who hve not een trined in the reommended serviing or instlltion proedures should hve the work performed y n uthorized Merury Mrine deler tehniin. Improper instlltion or serviing of the Merury produt ould result in dmge to the produt or personl injury to the instller or persons operting the produt. Qty. Desription Prt Numer 2 Exhust tue (exhust elow to intermedite exhust elow) 32 44358001 2 Exhust tue (use with originl exhust Y pipe) 32 807458T 2 Exhust tue (use with new exhust Y pipe) 32 44348 8 Hose lmps 54 815504272 2 Gsket elow, 4 slot 27 863726 12 Srew 3/8 16 x 4 5/8 in. (542 mm) long 10 53728 4 Srew 3/8 16 x 1 1/4 in. (32 mm) long 10 58640 4 Wsher split 13 41471 8 Srew 3/8 16 x 5 3/4 in. (146 mm) long 10 43749 3 Srew 1/4 20 x 3/4 in. (19 mm) long 10 65746 3 Srew set pressure rod 10 65746 3 Sper nylon 23 806981 3 Wsher stinless steel 12 35462 3 Nut 1/4 20 hex stinless steel 11 64015 Qty. Desription Prt Numer 2 Exhust elow 807988A2 2 Exhust mnifold 99746A17 1 Y pipe ssemly (lower exhust pipe) optionl only required if repling the existing Y pipe 807130A4 2 Intermedite exhust elow (for use without exhust risers) 14478T01 90-864294001 AUGUST 2005 2005 Merury Mrine Pge 1 / 8
Removl NOTE: If exhust risers re eing dded to this kit: Refer to the pproprite Merury Aessories Guide to identify the orret prt numers for the exhust riser kit nd intermedite exhust elow kit for your pplition. IMPORTANT: The instlltion of the two piee exhust mnifold will result in the loss of 12.7 mm (1/2 in.) of exhust elow height. Prior to removing the originl exhust mnifold, it is reommended tht the exhust elow height ove the wterline e heked. Refer to the pproprite Merury MerCruiser Instlltion Mnul. If the urrent exhust elow height minus 12.7 mm (1\2 in.) is not within the minimum exhust elow height speifition limits it will e neessry to order nd instll the pproprite exhust riser kit nd intermedite exhust elow. 1. If repling the Y pipe (lower exhust pipe):. Remove the engine nd the exhust tue ssemly from the ot. Refer to the pproprite Merury MerCruiser Servie Mnul.. Instll the new Y pipe (lower exhust pipe) ssemly. Refer to the pproprite Merury MerCruiser Servie Mnul. Remove nd retin the omponents mounted on the exhust mnifolds. d. Disonnet the wter hose from the fitting on the ottom of the exhust mnifold. e. Remove nd disrd the existing one piee exhust mnifolds. Refer to the pproprite Merury MerCruiser Servie Mnul. NOTE: The following steps n e performed with the engine in the ot. 2. If the Y pipe (lower exhust pipe) is not eing repled:. Remove nd retin the omponents mounted on the exhust mnifolds. Disonnet the wter hose from the fitting on the ottom of the exhust mnifold.. Remove nd disrd the existing one piee exhust mnifolds. Refer to the pproprite Merury MerCruiser Servie Mnul. - One piee exhust mnifold - Exhust tue 17112 - Wter hose Instlltion 1. Apply Selnt to the new wter hose fittings nd instll in the exhust mnifolds. Tighten seurely nd position towrd the front of the engine, fing slightly outord (pproximtely 5 10 degrees). Pge 2 / 8 90-864294001 AUGUST 2005
Tue Ref No. Desription Where Used Prt No. 19 Perfet Sel Wter hose fitting 92-34227-1 2. Instll the new exhust mnifolds with the new gskets. Refer to the pproprite Merury MerCruiser Servie Mnul. Torque the exhust mnifold srews. - Exhust mnifold - Exhust mnifold srew (6 eh side) 17104 - Wter hose fitting Desription Nm l. in. l. ft. Exhust mnifold srew 34 25 3. On 1996 Models:. Remove the nut tht seures the port wter hose lmp to the engine lok.. Disonnet nd disrd the lmp.. Reinstll nd torque the port wter hose lmp nut. Desription Nm l. in. l. ft. Port wter hose lmp nut 34 25 d. Route the port wter hose eneth the power steering pump. 17106 - Port wter hose routed eneth the power steering pump 90-864294001 AUGUST 2005 Pge 3 / 8
4. Reonnet the port wter hose to the wter hose fitting on the ottom of the port exhust mnifold. Tighten the hose lmp seurely. - Port wter hose 17107 5. Ensure tht the wter shutters re in good ondition nd orretly instlled in the exhust Y pipe (lower exhust pipe). Refer to the pproprite Merury MerCruiser Servie Mnul. 6. Apply selnt to the threds of the pipe plugs nd instll the pipe plugs into the new exhust elows. Tighten 1 nd 1\2 turns pst hnd tight. Tue Ref No. Desription Where Used Prt No. 9 Lotite 567 PST Pipe Selnt Pipe plug 92-809822 7. Apply selnt to the threds of the exhust elow to exhust mnifold srews. 8. Apply lierl ot of selnt to oth sides of the exhust elow to exhust mnifold gsket. Tue Ref No. Desription Where Used Prt No. 19 Perfet Sel Exhust elow to exhust mnifold srews nd exhust elow to exhust mnifold gsket 92-34227-1 9. Instll the exhust elows to the exhust mnifolds using the new gskets nd srews. Torque the srews. Desription Nm l. in. l. ft. Exhust elow to exhust mnifold srew 59 44 10. Connet the intermedite exhust elows to the exhust elows with the exhust tues nd lmps inluded in the kit. Tighten the lmps seurely. 11. Reinstll the engine, if it ws removed. Refer to the pproprite Merury MerCruiser Servie Mnul. Exhust Alignment And Instlltion Due to the vrition in trnsom thikness nd trnsom ngle, it will e neessry to mesure the lignment of the intermedite exhust elow to the exhust Y pipe. If there is forwrd over lp or rer overlp of the exhust Y pipe tht exeeds 9.52 mm (3/8 in.), it will e neessry to mke djustments using the following proedures to gin the orret lignment. Pge 4 / 8 90-864294001 AUGUST 2005
1. Do not instll the lower exhust tue t this time. 4.3L (262 CID) MANIFOLD CONVERSION 2. If the intermedite elow overlps the exhust Y pipe to the rer y more thn 9.52 mm (3/8 in.): 17728 Rer overlp of the exhust Y pipe shown, forwrd overlp similr - Lotion for mesurement of overlp - Intermedite exhust elow - Y pipe (lower exhust pipe). Remove the intermedite exhust elow from the upper exhust tue.. Cut pproximtely 12.7 mm (1/2 in.) off of the upper portion of the intermedite exhust elow. 17725 - Lotion of ut - Upper portion of the intermedite exhust elow. Instll the modified intermedite exhust elow into the upper exhust tue. d. Verify proper lignment of the intermedite exhust elow to the exhust Y pipe. e. Remove the intermedite exhust elow. f. Apply sop nd wter solution to the outer surfe of the exhust Y pipe. 90-864294001 AUGUST 2005 Pge 5 / 8
g. Slide the orret lower exhust tue onto the the exhust Y pipe s low s possile. Bell mouth Y pipe 17109 - Lower exhust tue 17726 Current prodution Y pipe - Y pipe (lower exhust pipe) h. Reinstll the modified intermedite exhust elow into the upper exhust tue. Tighten the hose lmps seurely. i. Pull the lower exhust tue up onto the lower portion of the intermedite exhust elow. Tighten the hose lmps seurely. d d e e 17110 - Exhust elow - Upper exhust tue - Intermedite exhust elow 17727 d - Lower exhust tue e - Y pipe (lower exhust pipe) Pge 6 / 8 90-864294001 AUGUST 2005
3. If the intermedite elow hs n overlp forwrd of the exhust Y pipe tht exeeds 9.52 mm (3/8 in.): 17728 Rer overlp of the exhust Y pipe shown; forwrd overlp similr - Lotion for mesurement of overlp - Intermedite exhust elow - Y pipe (lower exhust pipe). Loosen the upper exhust tue hose lmps t the intermedite exhust elow.. Pull the intermedite exhust elow wy from the exhust elow to eliminte the forwrd overlp nd hieve proper lignment with the exhust Y pipe.. Verify proper lignment of the intermedite exhust elow to the exhust Y pipe. d. Remove the intermedite exhust elow. e. Apply sop nd sop nd wter solution to the outer surfe of the exhust Y pipe. f. Slide the orret lower exhust tue onto the the exhust Y pipe s low s possile. 17109 - Lower exhust tue 17726 - Y pipe (lower exhust pipe) g. Reinstll the intermedite exhust elow into the upper exhust tue. Tighten the hose lmps seurely. 90-864294001 AUGUST 2005 Pge 7 / 8
h. Pull the lower exhust tue up onto the lower portion of the intermedite exhust elow. Tighten the hose lmps seurely. d d e e 17110 - Exhust elow - Upper exhust tue - Intermedite exhust elow 17727 d - Lower exhust tue e - Y pipe (lower exhust pipe) 4. Reinstll ll the omponents previously removed from the exhust mnifolds. Produts of Merury Mrine W6250 Pioneer Rod Fond du L, WI 54936-1939 Merury, Merury Mrine, MerCruiser, Merury MerCruiser, Merury Ring, Merury Preision Prts, Merury Propellers, Mriner, Quiksilver, #1 On The Wter, Alph, Brvo, Pro Mx, OptiMx, Sport-Jet, K-Plnes, MerCthode, RideGuide, SmrtCrft, Zero Effort, M with Wves logo, Merury with Wves logo, nd SmrtCrft logo re ll registered trdemrks of Brunswik Corportion. Merury Produt Protetion logo is registered servie mrk of Brunswik Corportion. Pge 8 / 8 90-864294001 AUGUST 2005