CONFIDENTIAL TIBU3614-00

The 100-6437 Exhaust Manifold Gasket that was used on these engines may allow an exhaust leak. The most frequent location of the leak is at the exhaust port of the number 2 cylinder

A new exhaust manifold gasket is now being used in the production of these engines. The new gasket is in effect with 3196 (2XR04843-Up) and C-12 (9HP00077) Marine Engines. This new exhaust manifold gasket is not yet available from the Parts System. An Engine News article will announce the availability of the new gasket.

Leaks at the exhaust manifolds can be confirmed by using a "white paper test". Place a piece of white card stock underneath each exhaust manifold port. The card stock must be positioned within one inch of the joint between the exhaust manifold and the cylinder head. Use a fixture to hold the card stock in position. Start the engine and run the engine for 20 to 30 seconds. Stop the engine and remove the card stock. There should be NO soot appearing on the card stock.

Until the new exhaust manifold gasket is available, the following repair procedure is recommended.

Note: Six 100-6437 Exhaust Manifold Gaskets are required for this procedure.

Note: Use the applicable Disassembly and Assembly Module as a guide for this procedure.

1. Remove the exhaust manifold assembly from the engine.
2. Clean the surfaces of the exhaust manifold and the cylinder head that contact the exhaust manifold gasket.
3. Assemble two 100-6437 Exhaust Manifold Gaskets together with the raised beads on the gasket toward the outside. Use several small beads of "super glue" to fasten the gaskets together. This will keep the gaskets in alignment until the exhaust manifold is installed. Repeat this procedure in order to provide 3 gasket assemblies.
4. Put the new exhaust manifold gasket assemblies (3) in position on the exhaust manifold (1).
5. Apply 5P-3931 Anti-Seize Compound to the threads of the 24 bolts (2) that fasten the exhaust manifold to the cylinder head. Install the 24 bolts (2) and washers. Tighten the 24 bolts (2) in the sequence shown in the illustration. Tighten the 24 bolts to a torque of 55 ± 10 N× m (41 ± 7 lb ft).

RIGHT SIDE VIEW
1. Exhaust Manifold, 2. 24 Bolts and Washers,
3. Exhaust Manifold Gasket

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