Just one bolt! Dang Merc designers!

[Gary H NC]

Changing manifolds on a 5.7.
It has the bracket with one bolt that goes into the exhaust manifold that holds the fuel filter housing and the Mercathode and main breaker...Starboard side...
It goes in from the backside of the bracket(hard to explain) but what a PIA!!!

Can i assume this was assembled before the whole darn engine went in?
I got the bolt out and manifold off but going back together is going to be a total pain.
Man i dread the job of getting that bolt back in..going at it at 6 am hoping i have a new attitude...

If anyone knows what i'm talking about and has any tips it would really be appreciated!

This job was going really smooth although you need arms the size of a 5 year old...me being a bob(big old boy) doesn't help much..

 

[JustJason]

Re: Just one bolt! Dang Merc designers!

Can't offer any advice.... But I feel your pain Gary.

 

[Don S]

Re: Just one bolt! Dang Merc designers!

Changing manifolds on a 5.7.

Like I ask (almost daily) what year, model number, SN, anything to help narrow down what you have.
The 5.7 has been used by Mercruiser since 69. Want to guess how many variations there have been in those 40 years ???

 

[Bt Doctur]

Re: Just one bolt! Dang Merc designers!

The bolt goes on from the front of the bracket thru the large spacer and just threads into the head.

 

[Gary H NC]

Re: Just one bolt! Dang Merc designers!

Sorry Don...2002 Mercruiser...5.7..don't have the serial handy at the moment.
It got dark and i have had it for the day..
Boat Doc hit it...thats the one...Threads into the front of the exhaust manifold through the bracket and spacer.

I removed the fuel line and lifted the manifold up to get a wrench on it.
Just seems like a crazy design..

Just had to vent a little.......:redface:
I'll have it back together in the morning...

 

[Bt Doctur]

Re: Just one bolt! Dang Merc designers!

you really should post a pic of this thing because all you do is remove the bolt and spacer, and remove the manifold, you dont need to remove fuel lines just the bolt and spacer and the exaust manifold falls off. do you have a normal bolt about 2 inches long or do you mean a stud in the ex manifold and a nut on the bracket.

 

[Gary H NC]

Re: Just one bolt! Dang Merc designers!

Its the regular bolt and spacer but the breaker and wiring prevents getting to it from the front...I think this was a rig job by the guy who installed the new engine and bolted up cracked manifolds with JB weld patch jobs on them..

I'm wired up with 3 cups of coffee and going out to jump on it..
I may see a whole different route this morning.I need to knock this out,i have 2 more waiting to get to,they all want them for the weekend.busy week!

What actually does the Mercathode box do? Mounted to the filter housing and breaker box.


I will let you know how it goes...Thanks!

 

[Gary H NC]

Re: Just one bolt! Dang Merc designers!

Amazing what a nights sleep will do.
Had the manifold and bracket back on in no time!
Run engine up to temp..no leaks! Let it cool and re-torque bolts.
Good to go...

Total parts and labor 787.50..I think thats a good deal for the customer.
New risers,manifolds,bolts,brass fittings and gaskets..

Not sure what a dealer would charge..