Follow the Leader! Important Information


Performance Boat Loans Service Bulletin No. 99-10 transcribed for web posting.
Scroll to bottom for Gasket Upgrade Kit

Exhaust Manifolds, Risers and Exhaust Elbows

Models: All boat V6 and V8 gasoline engines with center outlet exhaust.

New Sealant: P/N 92-804874 LOCTITE 510 Sealant - 250 mL Tube.

Fastener Torque Change: 33 lb-ft. Use this new torque on all fasteners when
installing exhaust elbows or risers onto exhaust manifolds.

Assembly:
1. Clean all gasket surfaces before reassembly.
2. Check the flatness of all gasket surfaces. Maximum overall is .003",
with not more than .001" difference within 1".

NOTE: Maximum material that can be removed is .010" to true a gasket surface up.
When torquing the attaching bolts, make sure that they are not bottoming out in the
manifolds threaded hole.

3. Look at the condition of the metal around the exhaust outlet casting. Inspect for
damaged metal caused by salt water or exhaust gas corrosion in the manifold, elbow
and riser (if equipped). Replace all damaged parts.

Top of manifold
a - Inspect area around exhaust outlet


4. Check the fire ring gasket fit on the manifold gasket surface. Place a new gasket on the
surface. Thread 4 short 3/8"-16 bolts into the holes. Move the gasket fore and aft,
then side to side to make sure the gasket's fire ring has manifold surface under all 4 positions.

NOTE: If the gasket's fire ring does not have a solid gasket surface in all 4 positions, the
manifold should be replaced.

Must be solid under all 4 areas
a- Gasket's fire ring has manifold gasket surface under all 4 positions.
b- Manifold gasket surface.

Improper surface area
a- gasket's fire ring does not have enough manifold gasket surface under it.
b- Manifold gasket surface.

5. There are 3 different types of fire ring gaskets.
P/N 27-860323 Gasket with 4 slots.
P/N 27-860233 Gasket-Restrictor with 2 holes and 2 slots. The 2 holes in the gasket always
go fore and aft.
P/N 27-860231 Gasket-Seperator without holes or slots. This gasket stops coolant flow.

NOTE: The type of gasket used in certain locations has changed from what is shown in older service literature.

1a. Raw water cooled engined with all the water from the thermostat houising going to the 90-degree fitting on the bottom of the exhaust manifold:
Use P/N 27-860232 Gasket between the exhaust manifold and the exhaust elbow.

If the engine has 3" or 6" risres, use P/N 27-860232 Gasket between the riser and the exhaust manifold and exhaust elbow.

1b. Raw water cooled engines with the bypass water forjm the thermostat housing going to
the fitting on the exhaust elbow and the warm water from the thermostat housing going to
the 90-degree fitting on the bottom of the exhaust manifold:

Use P/N 27-860233 Restrictor Gasket between the exhaust manifold and the exhaust elbow.

If the engine has 3" or 6" risers, use P/N 27-860233 Restrictor Gasket
between the riser and the exhaust elbow. Use P/N 27-860232 Gasket between the exhaust
manifold and the riser.

2a. Closed cooled engines with the raw water from the heat exchanger going to the 90-degree fitting at the bottom of the manifold:

Use P/N 27-860232 Gasket between the exhaust manifold and the exhaust elbow.

If the engine has 3" or 6" rises, use P/N 27-860232 Gasket between the riser and the exhaust manifold and exhaust elbow.

2b. Closed cooled engines with the exhaust manifolds closed cooled and the raw water
from the heat exchanger going to the fitting on the exhaust elbow:

Use P/N 27-860231 Seperator Gasket between the exhaust manifold and the exhaust elbow.

If the engine is has 3" or 6" risres, use P/N 27-860231 Seperator gasket
between the exhaust manifold and the riser. Use P/N 860232 Gasket between the
riser and the exhaust elbow.

Important: The use of gasket or sealant other than the ones specified in this
bulletin are not recommended.

6. Apply a 1/8" bead of LOCTITE 510 sealant P/N 92-804874 around all holes on
both sides of a new fire ring gasket.

Apply a 1/8 bead of LOCTITE 510 sealant around all holes
a- Apply a 1/8" bead of LOCTITE 510 Sealant

7. Assemble parts and torque fasteners to 33 lb-ft.

8. Allow sealant to cure for 2-3 hours before starting engine.

End of Bulletin




Don't chance blowing YOUR engine!

Get the latest Gasket Upgrade Kit for only $108.50
Kit includes gaskets and Sealant for one engine.

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