www.iFourWinns.com

The first time you do these jobs it's always a learning experience and the second time it goes much easier. I like to put some OMC gasket sealer on the threads of the bolts or studs because it keeps out moisture and the bolts come right out. I use it on the thermostat housing and I have never had a problem removing those bolts. I hear that some use anti-seize but it can cause trouble in salt water.
Heat stroke is bad news, drink some water before you start, and take breaks every so often. Those parts are heavy aren't they!
The good news is its easily do-able by a backyard mechanic. Have you ever seen what a horror show you have to deal with when the exhaust passage rots out on an outboard? There is a big thread over at the Hull Truth about this on Yamaha 4 strokes. You have to remove the powerhead and replace some very expensive parts. So inboards while they may be more work over time, do have their good points.

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88 Four Winns 200 Horizon
4.3 OMC Cobra-4bbl
2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

I've fixed many an engine in my time, so I know the range of hassles to be encountered. I'm thankful the boat manifolds are cooled. I've cursed many a blue streak while dealing with automotive exhaust studs.

Never had to deal with a modern outboard though, but it doesn't surprise me to hear about complications. There's only so many ways you can engineer something before it gets complicated. All that 'convenience' of an outboard comes at a cost, I guess.

The parts aren't all that heavy, maybe 50# each? The elbows feel like the heavier part. Now, had I not been able to separate the elbow from the manifold then, yeah, the combination of the two would've been a bitch to heave out of the engine compartment.

I was drinking a lot of water the whole time. It was just the combination of exertion and the ambient temperature (and humidity) that just suddenly hit me like a proverbial ton of bricks. I tend to work like a machine when there's a big task at hand. No interruptions, just grind through. I'll handle things differently today, lesson learned.

I'm not entirely sure how dressed the manifolds will be. I don't know if they'll come with the end plugs or not. Hopefully they will, but if not I'll put the old ones.

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-Bill Kearney, 2005 348 Vista

Good news is the job was a success. Took it out for about an hour's cruise, mostly at WOT and no overheating. So now we're good to go for a trip to St. Michael's next weekend. You do not want to be the husband that has to tell his wife that another weekend trip will be cancelled...

The manifolds and elbows came fully painted. I had to remove the paint from the mating surfaces. This was a hassle. I hit with a sander to scuff off the blue paint to reveal the black primer. This I removed with acetone. Another hour wasted, grrr....

But they went back on pretty easily. The manifolds being on studs, instead of using bolts, made it very easy. I really had to muscle the elbows into the exhaust hose, that was about the hardest part. The install used some 3.5" hose to act as a bushing, of sorts, to the final exhaust hose. Bit sketchy if you ask me, but it seemed to work OK before.

I'm still not getting full RPMs, but I have yet to replace the plug wires and do the injectors. That'll have to wait until next month. I'm about up to HERE with boat fixing...

Today I had to replace a 'blower control module' in my Grand Cherokee. Will the breakdowns never stop? Yeesh. $50 online but I've got a 3 hour drive first thing tomorrow, so I had to get bent over for it locally. But at least now I have working AC again. I did not want to entertain a 3 hour trip with the wife and child in 90F heat and no AC...

Now, off to load up fresh episodes of Jake and the Neverland Pirates onto the iPad...

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-Bill Kearney, 2005 348 Vista