Exhust System Generl Informtion Tle of Contents Section 7A - Generl Informtion Generl Informtion All Models... 7A-2 Exhust System Notice...7A-2 Reference Note...7A-2 Exhust System Connections...7A-2 Through the Hull Exhust Fittings... 7A-2 Generl Informtion Ctlyst Models... 7A-2 Preventing Contmintion of the Emissions Control System... 7A-2 Determining Ctlyst Helth... 7A-3 Mesuring Exhust Elow Height All Models... 7A-3 Generl Informtion... 7A-3 Bot Requirements... 7A-5 Loding Requirements...7A-5 Loding the Bot (Bots with Cpcity Plte)... 7A-6 Loding the Bot (Bots without Cpcity Plte)... 7A-8 Cler Hose Mesurement Method...7A-10 Cler Hose Mesurement Method from Muffler Drin... 7A-11 7 A 90-8M0081787 NOVEMBER 2013 Pge 7A-1
Generl Informtion Generl Informtion All Models Exhust System Notice NOTICE Improperly designing, instlling, or modifying the engine s exhust system cn introduce sewter or wter from condenstion into the comustion chmers, dmging the engine. The instlling deler or otuilder is responsile for proper instlltion of the exhust system s explined in the instlltion instructions for the product. Engine dmge resulting from wter ingestion is not covered y the product wrrnty, unless the dmge is the result of defective prt supplied y the engine mnufcturer. Reference Note Refer to the pproprite Mercury MerCruiser Product Applictions Mnul for vessel integrtion, ppliction, nd exhust systems instlltion requirements. Exhust System Connections IMPORTANT: The exhust system supplied y Mercury MerCruiser is complint with the ABYC Stndrd P 1. If components re used in ny portion of the exhust system tht modify the design of the supplied system, it is the otuilder's responsiility to ensure tht the new system complies with the ABYC Stndrds. Exhust system connections to components other thn those supplied y Mercury MerCruiser must use two stinless steel clmps with minimum width of 13 mm (1/2 in.) t ech joint. Through the Hull Exhust Fittings Exhust fittings (flnges, outlets) must e equipped with n internl shutter nd externl flpper to prevent wter intrusion prolems. This is requirement on ll pplictions except wter lift mufflers, where it is still recommended. A vriety of fittings re ville through the Mercury Precision Prts nd Accessories Guide. 13377 Generl Informtion Ctlyst Models Preventing Contmintion of the Emissions Control System Ctlyst nd oxygen sensors cn ecome contminted, leding to component filure. Phosphorus, found in some mrine grde oils, nd other compounds will dmge or destroy ctlyst's ility to clen the exhust. Ctlyst friendly oil, like Mercury Full Synthetic MerCruiser Engine Oil, prevents this dmge. Approved synthetic oils must e used in MerCruiser engines with emissions control. NOTICE Acetoxy silicone selnts nd other compounds cn dmge oxygen sensors nd ctlysts. Use only compounds nd selnts pproved y Mercury Mrine for use on ctlyzed engines, such s Loctite 587 High Performnce Blue. Fierglss is silic sed mteril tht cn contminte the ctlyst nd the oxygen sensors. To reduce the possiility tht the engine will ingest hrmful fierglss nd poison the emission control components, protect the engine from fierglss dust nd deris during construction nd clenup. Pge 7A-2 90-8M0081787 NOVEMBER 2013
Determining Ctlyst Helth Generl Informtion Ctlyst helth cn e determined y oserving onord dignostics mrine (OBD M) ctlyst monitor rtios with CDS G3. Remove the ctlyst from the exhust mnifold for inspection only if live dt indictes tht ctlyst my e compromised. Below is n exmple of Live Dt screen t completion of the ctlyst monitor test. Actul vlues my differ. Note tht the ctlyst monitor rtios indicte tht oth ctlysts my e dmged. c CDS G3 Live Dt screen - Pre O2 sensor monitor finished - Port nd strord ctlyst monitors finished c - Ctlyst response times (ll less thn 0.92 seconds) d - Port ctlyst monitor rtio filed (vlue is less thn 1) e - Strord ctlyst monitor rtio filed (vlue is less thn 1) The time it tkes for the pre O2 sensor to trnsition from rich to len compred to the post O2 sensor vlue is directly relted to the ctlyst's oxygen storge cpcity (OSC). The OSC is mesured in milligrms. If the ctlyst monitor rtio is elow 1.00, nd the ctlyst response time is elow 0.92 seconds, inspect the ctlyst for dmge. Use known good O2 sensors nd repet the test if the ctlyst monitor rtio is elow 1.00 nd the ctlyst response time is ove 0.92 seconds. Refer to Service Mnul #49 PCM 09 Dignostics for informtion out ctlyst monitor testing with CDS G3. Mesuring Exhust Elow Height All Models Generl Informtion Instll exhust elows within the specified height dimensions to prevent wter intrusion. Instll exhust elow risers s needed to otin the proper exhust elow height nd exhust ngle. Risers cnnot exceed 203.2 mm (8 in.). Tke ll mesurements with the ot in the wter nd loded to simulte the mximum loding conditions for norml opertion. IMPORTANT: If instlling wter lift muffler, mesure the elow height to the wterline inside the wter lift muffler, not the wterline outside of the ot. Refer to Cler Hose Mesurement Method from Muffler Drin for instructions. IMPORTANT: The ot mnufcturer is responsile for lod distriution recommendtions. Botuilders must communicte ny lod distriution conditions tht ffect the exhust system, such s mximum occupncy of the swim pltform, to the opertor in the owner's mnul. Mesurements for ll loding conditions must meet the following specifictions: Model d e Minimum Exhust Elow Height (ove wterline) 8.2 ECT sterndrive models 33 cm (13 in.) 54085 90-8M0081787 NOVEMBER 2013 Pge 7A-3
Generl Informtion Model Minimum Exhust Elow Height (ove wterline) 8.2 inord models nd non ECT sterndrive models 38 cm (15 in.) Model Minimum Exhust Hose Slope within 45.7 cm (18 in.) of Engine Minimum Exhust Hose Slope Reminder of System (if pplicle) 8.2 10 3 If the exhust elow height or exhust ngle is insufficient, modify the exhust system or instll the pproprite exhust riser. Refer to the pproprite Mercury Precision Prts nd Accessory Guide for prt numers. The mximum exhust riser height is specified in the tle elow. Exhust Riser Options Model Low Medium High 8.2 nonctlyzed 51 mm (2 in.) 152 mm (6 in.) 203 mm (8 in.) 8.2 triple ctlyst models 8.2 single ctlyst models Model 51 mm (2 in.) 102 mm (4 in.) 152 mm (6 in.) 51 mm (2 in.) 102 mm (4 in.) 152 mm (6 in.) Minimum Exhust Hose or Tue length 8.2 sterndrive models 30 cm (12 in.) 8.2 inord models 46 cm (18 in.) Exhust Angle Mesurement Mesure the exhust ngle of ech section of the exhust system using n inclinometer s shown in the digrm elow. Begin the mesurement t the exhust elow outlet continuing long ech section to the exhust exit point of the ot. Perform ll exhust ngle mesurements with the ot t rest in the wter. Perform the first set of mesurements without lod in the ot. Perform the second set of mesurements with the ot fully loded. See Loding Requirements. c Models without emissions control - Inclinometer - Exhust hose or tue c - Length of exhust hose or tue 8235 Pge 7A-4 90-8M0081787 NOVEMBER 2013
Generl Informtion Triple ctlyst design - Length of exhust hose or tue - Inclinometer c - Exhust hose or tue c 31667 Single ctlyst design - Length of exhust hose or tue - Inclinometer c - Exhust hose or tue c Bot Requirements IMPORTANT: Consider the following requirements efore performing the exhust elow wterline height mesurement. No prototype hulls or light lyup hulls should e considered. Any mesurement performed on nonproduction ots, prototype hulls, or light lyup hulls could e inccurte nd could result in product dmge. All ots tht disply CE certifiction cpcity plte must use the mximum cpcity s stted on the CE certifiction cpcity plte to perform the exhust elow wterline mesurement. All ots tht only disply the US Cost Gurd (USCG) cpcity plte must use the mximum cpcity s stted on the USCG cpcity plte to perform the exhust elow wterline mesurement. For ots tht do not hve cpcity plte, the mximum cpcity lod is the numer of persons tht cn sit on designted seting plus crgo excluding cin spce. Mesurements used for officil Mercury MerCruiser udit t the OEM otuilder must e performed on current production ots. No prototype hulls or light lyup hulls will e considered for officil udit purposes. Mesurements used for officil Mercury MerCruiser udit t the OEM otuilder must use the CE certifiction mximum lod for ny ot model tht will e sold outside of the United Sttes. Loding Requirements 1. Fill the fuel tnks, fresh wter tnks or holding tnks, llst tnks, nd heter tnks to simulte fully loded condition. 2. Weights cn e used to simulte these lod conditions if desired. Plce weights in the corresponding re for which the lod is eing replced. Refer to the following conversions. 1 U.S. gllon of wter = 8.3 l 1 liter of wter = 1 kg 1 U.S. gllon of gsoline = 6 l 1 liter of gsoline = 0.72 kg 90-8M0081787 NOVEMBER 2013 Pge 7A-5 50437
Generl Informtion 3. For the purpose of MerCruiser wterline height mesurements: One person is equivlent to 74.84 kg (165 l) Crgo per person is equivlent to 11.34 kg (25 l) 4. Add weight for ny dditionl ot options: extr ttery, ttery chrger, tower, rch, genertor, llst tnks, llst scks, television, crpet, nchor, stereo/entertinment equipment, wsher/dryer, sfe, etc. 5. If swim pltform is n option, the swim pltform must e instlled for the wterline height mesurement. Use the following guide to determine the correct swim pltform lod:. Bots less thn 8.84 m (29 ft) long, not including ots tht re 8.84 m (29 ft) long, must dd the mximum rted swim pltform weight cpcity to the swim pltform.. Bots less thn 8.84 m (29 ft) long, not including ots tht re 8.84 m (29 ft) long, tht do not hve mximum rted swim pltform weight cpcity, must dd 181.45 kg (400 l) to the swim pltform. c. Bots 8.84 m (29 ft) long nd greter thn 8.84 m (29 ft) long, must dd the mximum rted swim pltform weight cpcity to the swim pltform. d. Bots 8.84 m (29 ft) long nd greter thn 8.84 m (29 ft) long, tht do not hve mximum rted swim pltform weight cpcity, must dd 226.80 kg (500 l) to the swim pltform. Loding the Bot (Bots with Cpcity Plte) For ots with cpcity plte, use the mximum lod for persons nd ger s listed on the cpcity plte to determine the numer of persons to plce onto the ot for exhust elow wterline height mesurements. IMPORTANT: Use 20 in. for n verge pssenger set width when mesuring ench seting. Round up or down t 0.5 to otin whole person. See the exmples listed elow. 48 in. (ench set length) 20 in. (set width) = 2.4 persons. 2.4 persons rounded down = 2 persons. 55 in. (ench set length) 20 in. (set width) = 2.75 persons. 2.75 persons rounded up = 3 persons. 1. Tke the mximum cpcity weight s listed on the cpcity plte (XXXX ls, persons, ger) nd sutrct the swim pltform lod, if pplicle. 2. Next divide the weight y 74.84 kg (165 l) per person. This gives the whole numer nd reminder of 74.84 kg (165 l) persons to lod onto the ot. 3. Put the reminder of person in the next ville set. See the ot loding digrm. 24860 24861 CE cpcity plte USCG cpcity plte IMPORTANT: If there is not enough seting for the numer of people, tret the leftover weight s crgo. Lod crgo weight onto the ot efore loding pssenger weight. 4. If pplicle, lod crgo (leftover persons weight) onto the ot. Distriute crgo s descried elow. IMPORTANT: If the ot configurtion does not llow for ft, center, nd ow storge, choose the storge ppliction from the Optionl Crgo Distriution tle tht est pplies to your ot configurtion. Preferred Crgo Distriution Aft storge Center storge Bow storge 25% 50% 25% Pge 7A-6 90-8M0081787 NOVEMBER 2013
Generl Informtion Optionl Crgo Distriution Aft storge Center storge Bow storge 25% 75% None None 75% 25% 50% None 50% None 100% None 100% None None None None 100% 5. Perform the first mesurement with the swim pltform loded nd the person tking the wterline mesurement on the ot. 6. Lod the swim pltform if equipped. 7. Mesure the exhust elow wterline height. IMPORTANT: View ll ot seting s rows tht re prllel to the trnsom of the ot. 8. Lod person weight into set, nd mesure the exhust elow wterline height fter ech person weight is loded onto the ot. Repet until person weight is loded into ech set in tht row. 9. Continue the process moving forwrd towrd the ow of the ot to the next row of sets until person weight is loded into ech set. NOTE: The totl weight loded onto the ot must not exceed the mximum cpcity displyed on the cpcity plte. NOTE: The following exmple is provided s reference. Exmple NOTE: This exmple uses ot tht is less thn 8.84 m (29 ft) long, not including ot tht is 8.84 m (29 ft) long tht does not hve mximum rted swim pltform weight cpcity, nd must dd 181.45 kg (400 l) to the swim pltform. NOTE: Use 0.50 l s the rek point to round up or down to otin whole pound. 1. Mximum lod (persons nd ger) from cpcity plte swim pltform lod = remining weight to e plced in the ot. 1100 l 400 l = 700 l 2. Remining weight to e plced in the ot MerCruiser person weight = numer of persons to lod onto the ot. 700 l 165 l = 4.24 persons 3. Totl numer of persons numer of whole persons = remining persons. 4.24 persons 4 persons = 0.24 remining persons 4. Reminder persons MerCruiser person weight = reminder MerCruiser person weight. 0.24 165 l = 40 l IMPORTANT: View ll ot seting s rows tht re prllel to the trnsom of the ot. 5. Using the totls in this exmple, lod four 165 l persons nd one 40 l person onto ot seting with 400 l on the swim pltform. 400 l + 165 l = 565 l 565 l + 165 l = 730 l 730 l + 165 l = 895 l 895 l + 165 l = 1060 l 90-8M0081787 NOVEMBER 2013 Pge 7A-7
Generl Informtion 1060 l + 40 l = 1100 l d c e f 24862 Bot loding digrm - Swim pltform lod - MerCruiser person weight (one) c - MerCruiser person weight (two) d - MerCruiser person weight (three) e - MerCruiser person weight (four) f - Reminder MerCruiser person weight (five) Loding the Bot (Bots without Cpcity Plte) For ots tht do not disply cpcity plte, the numer of persons to e loded onto the ot for mesuring purposes is the numer of persons tht cn sit on designted seting excluding cin spce. An dditionl weight of 25 l per person is to e dded to the ot efore loding pssenger weight onto the ot. IMPORTANT: Use 20 in. for n verge pssenger set width when mesuring ench seting. Round up or down t 0.5 to otin whole person. See the exmples elow. 48 in. (ench set length) 20 in. (set width) = 2.4 persons. 2.4 persons rounded down = 2 persons. 55 in. (ench set length) 20 in. (set width) = 2.75 persons. 2.75 persons rounded up = 3 persons. 1. Totl numer of persons tht cn sit on designted seting excluding cin spce MerCruiser person weight = mximum pssenger lod for mesurement. Numer of persons 165 l (MerCruiser person weight) = XXXX l mximum pssenger lod. 2. Mximum pssenger lod from the clcultion ove swim pltform lod if pplicle. 3. Divide the weight y 165 l per person. This gives the numer of 165 l persons to lod onto the ot. Round up to next whole numer. See Exmple 3. IMPORTANT: To ccount for crgo, dd weight of 25 l per person to the ot efore loding pssenger weight onto the ot. 4. Clculte the crgo y multiplying 25 l y the numer of persons tht cn sit on designted seting excluding cin spce. See Exmple. 5. Lod the crgo onto the ot. Distriute crgo s descried elow. IMPORTANT: If the ot configurtion does not llow for ft, center, nd ow storge, choose the storge ppliction from the Optionl Crgo Distriution tle tht est pplies to your ot configurtion. Preferred Crgo Distriution Aft storge Center storge Bow storge 25% 50% 25% Pge 7A-8 90-8M0081787 NOVEMBER 2013
Generl Informtion Optionl Crgo Distriution Aft storge Center storge Bow storge 25% 75% None None 75% 25% 50% None 50% None 100% None 100% None None None None 100% 6. Perform the first mesurement with the swim pltform loded nd the person mesuring the wterline on the ot. 7. Lod the swim pltform if equipped. 8. Mesure the exhust elow wterline height. IMPORTANT: View ll ot seting s rows tht re prllel to the trnsom of the ot. 9. Lod person weight into set, nd mesure the exhust elow wterline height fter ech person weight is loded onto the ot. Repet until person weight is loded into ech set in tht row. 10. Continue the process moving forwrd towrd the ow of the ot to the next row of sets until person weight is loded into ech set. Exmple NOTE: The following exmple is provided s reference. This exmple uses ot tht is 8.84 m (29 ft) long nd greter thn 8.84 m (29 ft) long, tht does not hve mximum rted swim pltform weight cpcity, nd must dd 226.80 kg (500 l) to the swim pltform. IMPORTANT: The Designted Seting Digrm following illustrtes the numer of pssengers tht cn sit on designted seting excluding cin spce. 2 1 3 4 5 7 8 6 9 24863 Designted seting digrm This exmple uses nine persons s the mximum pssenger lod. NOTE: Use 0.50 l s the rek point to round up or down to otin whole pound. 1. To determine the mximum crgo lod multiply the mximum pssenger lod y the mximum crgo weight per pssenger. 9 pssengers 25 l = 225 l 2. To determine the preferred crgo distriution for ft, center, nd ow storge:. To determine the mximum ft storge crgo weight, multiply the mximum crgo weight y 25%. 3. To determine the mximum center storge crgo weight, multiply the mximum crgo weight y 50%.. 225 l 50% = 112.50 l. 112.50 l rounded up = 113 l 4. To determine the mximum ow storge crgo weight, multiply the mximum crgo weight y 25%. 225 l 25% = 56.25 l 56.25 l rounded down = 56 l 5. To determine the mximum numer of pssengers to lod onto the ot, multiply 9 pssengers y 165 l (MerCruiser person weight) to get 1485 l (totl pssenger lod). 9 pssengers 165 l = 1485 l 6. Sutrct the swim pltform lod from the totl pssenger lod to get the remining weight to e plced in the ot. 1485 l 500 l = 985 l 90-8M0081787 NOVEMBER 2013 Pge 7A-9
Generl Informtion 7. Divide the remining weight to e plced onto the ot y the MerCruiser person weight to get the mximum numer of pssengers to lod onto the ot. 985 l 165 l = 5.9 pssengers 5.90 pssengers rounded up = 6 pssengers 8. Using the totls in this exmple lod 56 l crgo in the ft storge, 113 l crgo in the center storge, nd 56 l crgo in the ow storge onto the ot efore dding pssenger weight. Then, lod six 165 l pssengers, onto the ot with 500 l on the swim pltform. 500 l + 225 l = 725 l 725 l + 165 l = 890 l 890 l + 165 l = 1055 l 1055 l + 165 l = 1220 l 1220 l + 165 l = 1385 l 1385 l + 165 l = 1550 l 1550 l + 165 l = 1715 l g c d h e f i j 24864 Crgo, swim pltform, nd pssenger weight loding digrm - Swim pltform lod - MerCruiser person weight (one) c - MerCruiser person weight (two) d - MerCruiser person weight (three) e - MerCruiser person weight (four) f - MerCruiser person weight (five) g - MerCruiser person weight (six) h - Aft storge i - Center storge j - Bow storge Cler Hose Mesurement Method 1. Otin n 8 10 mm (5/16 3/8 in.) inner dimeter (ID) cler hose pproximtely 4.5 m (15 ft) long. Instll metl fitting or weight on one end of the hose to keep tht end of the hose elow the wterline. The fitting or weight must not restrict wter from filling the cler hose. c - Cler hose - Fitting c - Unrestricted opening IMPORTANT: On engines equipped with more thn one exhust elow, perform the exhust elow wterline height mesurement on the side tht sits lower in the wter. 2. Put the weighted end of the cler hose over the side of the ot (port or strord) tht is sitting lower in the wter. 3. Sumerge the cler hose until completely filled with wter. Pge 7A-10 90-8M0081787 NOVEMBER 2013 24865
4. Plce finger over the open end of the cler hose efore removing it from the wter. 5. Coil the excess cler hose into the ottom of the ot ilge. Keep the coil of cler hose elow the wterline. Generl Informtion 6. Keeping the cler hose in line with the engine's exhust elow, lift the end of the cler hose up to the highest point of the exhust mnifold collector nd elow. 7. Slowly tke the finger off of the end of the cler hose to let the wter level stilize. The wter will seek the level of the wter outside of the ot. Keep the cler hose close to the exhust elow nd s verticl s possile. dc d - Wterline - Top of exhust elow c - Wterline to top of exhust elow mesurement d - Cler hose e - Weight Cler Hose Mesurement Method from Muffler Drin IMPORTANT: Mesure the exhust elow height to the wterline inside of the wter lift muffler (insted of the wterline outside of the ot) on pplictions so equipped. IMPORTANT: The engine must hve een operted previously to fill the muffler with wter. IMPORTANT: On engines equipped with more thn one exhust elow, perform the exhust elow wterline height mesurement on the side tht sits lower in the wter. 1. Attch cler hose to the muffler drin point or secock drin point. 2. Strt the engine to fill the muffler nd hose. 3. If ttched to the secock drin, open the secock. 4. Route the reminder of the hose towrd the engine's exhust mnifold nd elow. Ensure tht this open end section of the hose is s verticl s possile from the ot's ilge to the top of the exhust elow. 5. Coil excess hose in the ilge of the ot, keeping it elow the wterline. 6. Lower the open end of the hose nd siphon wter until it strts to come out of the hose. Put finger over the hose nd lift open end until it is t the top of the exhust elow. 7. Slowly tke the finger off of the end of the hose to let the wter level stilize. The wter will seek the level of the wter outside the ot. Keep the hose close to the exhust elow nd s verticl s possile. 8. The mesurement etween the wter in the hose nd the top of the exhust elow is the exhust elow height. The mximum riser height is 20.3 cm (8 in.) on 8.2 models. 33026 e Typicl verticl wter lift muffler without ctlyzed exhust - Cler hose for mesuring wterline - Minimum exhust elow height with mximum lod 54027 90-8M0081787 NOVEMBER 2013 Pge 7A-11
Generl Informtion IMPORTANT: Horizontl wter lift mufflers re permitted for use only if the ottom of the muffler is elow the crnkshft centerline. Typicl horizontl wter lift muffler without ctlyzed exhust - Cler hose for mesuring wterline - Minimum exhust elow height with mximum lod 54028 54024 Typicl verticl wter lift muffler triple ctlyst mnifold - Cler hose for mesuring wterline - Minimum exhust elow height with mximum lod IMPORTANT: Horizontl wter lift mufflers re permitted for use only if the ottom of the muffler is elow the crnkshft centerline. 54025 Typicl horizontl wter lift muffler triple ctlyst mnifold - Cler hose for mesuring wterline - Minimum exhust elow height with mximum lod Pge 7A-12 90-8M0081787 NOVEMBER 2013
Generl Informtion 50428 Typicl verticl wter lift muffler single ctlyst mnifold - Cler hose for mesuring wterline - Minimum exhust elow height with mximum lod IMPORTANT: Horizontl wter lift mufflers re permitted for use only if the ottom of the muffler is elow the crnkshft centerline. 50431 Typicl horizontl wter lift muffler single ctlyst mnifold - Cler hose for mesuring wterline - Minimum exhust elow height with mximum lod 90-8M0081787 NOVEMBER 2013 Pge 7A-13
Generl Informtion Notes: Pge 7A-14 90-8M0081787 NOVEMBER 2013