Torque specs for exhaust manifold/divider plate

crawfw

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May 26, 2009
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I have a water leak at my exhaust manifold. Looks to be the outer gasket between the manifold and divider plate. The motor is a 1988 merc XR4 150hp. I have gaskets on the way and need to find the torque specs for install. Thanks in advance for any replies. Also would like to find the proper repair manual for this motor. Serial # is 0B304074.
 

Texasmark

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Dec 20, 2005
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The bolts are probably 5/16. Do a google search on ASME (American Society of Mechanical Engineers) torque specs and in the chart find your size, material and condition of the medium...corroded, threads chased, lubricated.

On getting your existing bolts out without breakage, impact is the only way to go. If you don't have a wrench use a regular boxed end wrench and a hammer. If you do have one put it on a low pressure setting.

Dose the bolts down with PB Blaster or better penetrating oil the night before you do the work. Probably won't do you any good as the paint probably is sealing off the bolt to the plate interface, but try it anyway.

Get on the bolt with your wrench holding in place with pressure on it with one hand and using the other with something like a 10oz ball peen hammer, start smaking the blot. As soon as you get it to break loose go to the next one till you have cracked them all.

Soak down with PB over night and the next day come back and try to get a half turn out, working your way around.

One more time, soak and come back the next day and you should be able to get them all out without damage.

When out, clean out the threads of the bolts with a power wire brush and run a 5/16 fine (as I recall...check the threads on the bolts) blind tap with more penetrating or thread cutting oil on the tap down each hole to clean out the threads. Blow the holes out with compressed air.

Upon installing, use Blue Thread Locker on the bolt threads before inserting. This will qualify them as wet threads when looking up the proper torque.

Personally, I'd forget the torque wrench and just run them all in snug then using an X pattern, like any plate be it an engine head or whatever, work your self from the center to the outside tightening as you go, 3 times. The last time would be after about an hour, giving the gasket time to settle in and back with the impact, smacking moderately until the bolt stops turning, then one more smack.

On the gasket, put it on wet, and wet means with Blue RTV silicone. The manual usually talks about dry, but after 50 years of fooling with engines, marine included, what is written in the book and real life are 2 different things. When the engine is built there is no corrosion and everything is new. After 20 years it's a whole new world and the RTV ensures you will not have to come back and won't break your bolts or strip your threads getting your cover back on without leaking.

That's how I'd do it. Others probably have other opinions.

Mark
 

Faztbullet

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Mar 2, 2008
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Personally, I'd forget the torque wrench and just run them all in snug then using an X pattern
Nope.... you need to follow torque pattern as you also have the divider spaghetti seal that need to be flattened evenly also. Tighten the bolts in a 3 steps 60,120,180inLbs. here is link..http://corboatracing.com/downloads/mercury-2.0-liter-torque-specs-2.pdf
On the gasket, put it on wet, and wet means with Blue RTV silicone.
Really No!!! You do not want to use silicon in this area due to it squishing out and entering water passages.If you are use the older aftermarket green or grey paper gaskets use avation gasket sealer. If using the newer black or green silicon inmpregnated it goes on dry, as does the newer gaskets with sealer lines.

gskt.jpg gskt1.jpg
 

crawfw

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May 26, 2009
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Thanks for the replies. I actually found the link with the bolt pattern tightening and the torque spec that Faztbullet pasted. I just didn't know if it was the right one being that my search found a few different results. I prob will use some sealant but it will be a slight amount so it doesn't squish to the outer part of the gasket. And as for the removing of the bolts, geesh, sounds like a nightmare. But I will follow the advice of the first reply on removing them.
 

Texasmark

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Dec 20, 2005
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Well I guess I just did mine horribly wrong over the years. Too bad they didn't upchuck and spank my hand. Like I said, that was the way I did it and others had other ideas, practices.
 

Dukedog

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Oct 6, 2009
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3,487
tha main reason not ta use a sealant is tolerance and gasket compression.... with yours is its "two" pieces which will increase tha chance of some excess ta find its way into some of tha waterin' holes... but like tex do what ya want... Merc doesn't know any better.
 

crawfw

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May 26, 2009
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Pretty easy job other than the gasket sealing surface cleanup. No silicone used. Blue thread locker used on bolts. Followed torque pattern in diagram. 60 then 120 then 180 in lbs. Used quicksilver gaskets and spaghetti divider seal. thanks all for the help.
 
Last edited:

CharlieB

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Apr 10, 2007
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5,617
Wet silicone will act like a lubricant. If the two surfaces are even slightly uneven the slick gasket will spit out like a tiddly-wink, tearing and if it slides to the inside you won't even see that it is torn and leaking.

I use silicone on most everything. As THIN as I can smear it. And let it dry at least 20 minutes before assembly. Never a tear. Never a leak. Even on the old Detroit 2-stroke Diesels.
 
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