How do you remove the elbows?!?

[makonnen]

1998 Bayliner 2655

I can't tell you how close I am to getting a sawzall and cut a chunk out of the deck ... how the heck do you remove the elbows from a Bayliner 2655 Ciera?? I'm used to owning boats with doghouses and its so easy to check the manifold, risers and elbows ...

On this boat, it looks like I have to put a 4x4x8' post across the gunnels, chain the manifolds to it and let go of the exhaust manifold. Either that or extract the studs but I bet they are seized in place.

Any tricks of the trade here??

 

[tpenfield]

Re: How do you remove the elbows?!?

I really do not see a problem . . .

After you drain down the manifolds, you would remove the control linkages from the elbows and then remove the 4 bolts attaching each elbow to the manifold. Loosen the clamps on the small section of flex hose and they are all yours.

Usually the elbows are taken off separately from the manifolds, so no heavy duty lifting is required.

If you need to further dis-assemble that exhaust tubes, they should come apart and out easily, once the elbows are removed.

 

[Bondo]

Re: How do you remove the elbows?!?

I really do not see a problem . . .

After you drain down the manifolds, you would remove the control linkages from the elbows and then remove the 4 bolts attaching each elbow to the manifold. Loosen the clamps on the small section of flex hose and they are all yours.

Usually the elbows are taken off separately from the manifolds, so no heavy duty lifting is required.

If you need to further dis-assemble that exhaust tubes, they should come apart and out easily, once the elbows are removed.

Ayuh,.... Agreed,.... Lot'sa room to work,...

'ell, I bet ya can even change the spark plugs,.. without pullin' the motor...

 

[Bt Doctur]

Re: How do you remove the elbows?!?

remove the 6 clamps in green, remove the dumps in blue, remove nuts, remove risers,
REPLACE studs with bolts

 

[muc]

Re: How do you remove the elbows?!?

I see your problem.

Ted and Bt Doctor are missing the fact that your elbows are held on with studs and the boat clearance won’t allow them to lift straight up with the 90 degree pipe still on.

The trick is a spray bottle with dish soap and water --- mixed about ? oz. soap to 6 oz. water. Trust me that soapy water will make all the difference.
Remove all 16 hose clamps --- a cordless drill with a 5/16” nut driver on it will speed the job up.
Now start working screw drivers between the lower rubber hose and the 90 degree pipe and the y-pipe. While doing this spray your soapy water mix into the gap between the rubber hose and metal pipes. Don’t be shy with the soapy water it will work as an lubricant to allow the rubber hose to slid down the y-pipe far enough to let you slide the 90 degree pipe out of the upper rubber hose. Now the elbow and riser will lift straight up off of the studs.
Note; getting the lower hose to slide down the y-pipe isn’t easy, especially if the hose is old and getting hard. But if you keep working the screwdrivers around the hose (stretching it a little bit) and spraying soapy water it will go. The biggest problem will come if the engine has had a good overheat at some point --- this will cause the rubber hose to get extra stiff and also burn the rubber in the area that is exposed between the two pipes. Makes it almost impossible to slide the hose down --- in that case it’s best to just cut the hose off and get a new one. Once hoses get that bad it rare to get them to seal back up when you reinstall them so you would want to replace them anyway.

 

[Bt Doctur]

Re: How do you remove the elbows?!?

Hard to actually tell is there is enough room to lift up . The shift cable was notched to I`m guessing this motor replaced an older model.
May have to notch the fiberglass to aid in removal.

 

[makonnen]

Re: How do you remove the elbows?!?

Trust me guys, I am not slouch when it comes to wrenching and I cannot separate the 90 degree downpipe from the elbow. It butts against the deck where I put the red circles.

Muc - that is an excellent suggestion, I will try that. I'm not looking forward to making a jig to do what should be a simple job.

BT Doc - Its so tempting, it looks like I need only 3/4 of an inch off the bottom of the deck to get this job done. But my common-sense radar tells me not to do that.

 

[ktbarrentine]

Re: How do you remove the elbows?!?

I had virtually the same condition in my 1990 20' chaparral w/ 5.0L when inspecting shutters. Using the "muc soapy water method" I was able to rotate the 90s outboard out of the upper boots, then tilt them outboard to get them out of the lower boots. Just took finesse... and patience, and lots of soap. Boots were in great shape, so was able to reuse.

 

[Bt Doctur]

Re: How do you remove the elbows?!?

the pic shows about 1 -1/2 of space above the dumps, maybe a circular cut for clearance
cut the rubber coupling boots off, though new ones will need some ingenuity
remove/cut the lower boots per kt and rotate to remove.

 

[achris]

Re: How do you remove the elbows?!?

One trick I use is to loosen all the clamps on the lower boot, push it down so the lower end of the 90 degree elbow is exposed, then loosen the clamps on the upper boot and slide the upper boot and 90 degree elbow towards the back of the boat. That should give you clearance to lift the elbow off the studs. If it doesn't, then I would be lifting the elbow as high as I could and cutting the studs off, then replacing them with long screws.

Chris.........

 

[Don S]

Re: How do you remove the elbows?!?

One trick I use is to loosen all the clamps on the lower boot, push it down so the lower end of the 90 degree elbow is exposed, then loosen the clamps on the upper boot and slide the upper boot and 90 degree elbow towards the back of the boat. That should give you clearance to lift the elbow off the studs. If it doesn't, then I would be lifting the elbow as high as I could and cutting the studs off, then replacing them with long screws.

Chris.........

Which is exactly what muc explained up in reply #5

 

[makonnen]

Re: How do you remove the elbows?!?

Thanks to everyone for the response and sorry for the late reply. I go into boat hibernation between September and now only to awaken remembering that I have a boat.

I followed these instructions to the T and it worked. Just to add to this instruction ... in case others are struggling with this ... Wedge the prybar between the elbow and rubber and stretch it out ... make it flexible. Put the soapy solution (I used Sunlight dish soap) in a squeeze bottle so you really soak things.

Once you get a good pry point, its not that hard to push the lower hose down the y point. I basically wedged the prybar across the opening of the 90 degree aluminum tube and cranked it downward after dousing the entire area with spoapy water. Within a minute it was free.

Below you can see the pic of how far I was able to push the rubber hose down ... about 2".

These are the implements of destruction. The black bottle is an old gear lube bottle I used to spray the soapy water.

Hope this helps someone else.

I see your problem.

Ted and Bt Doctor are missing the fact that your elbows are held on with studs and the boat clearance won’t allow them to lift straight up with the 90 degree pipe still on.

The trick is a spray bottle with dish soap and water --- mixed about ? oz. soap to 6 oz. water. Trust me that soapy water will make all the difference.
Remove all 16 hose clamps --- a cordless drill with a 5/16” nut driver on it will speed the job up.
Now start working screw drivers between the lower rubber hose and the 90 degree pipe and the y-pipe. While doing this spray your soapy water mix into the gap between the rubber hose and metal pipes. Don’t be shy with the soapy water it will work as an lubricant to allow the rubber hose to slid down the y-pipe far enough to let you slide the 90 degree pipe out of the upper rubber hose. Now the elbow and riser will lift straight up off of the studs.
Note; getting the lower hose to slide down the y-pipe isn’t easy, especially if the hose is old and getting hard. But if you keep working the screwdrivers around the hose (stretching it a little bit) and spraying soapy water it will go. The biggest problem will come if the engine has had a good overheat at some point --- this will cause the rubber hose to get extra stiff and also burn the rubber in the area that is exposed between the two pipes. Makes it almost impossible to slide the hose down --- in that case it’s best to just cut the hose off and get a new one. Once hoses get that bad it rare to get them to seal back up when you reinstall them so you would want to replace them anyway.