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Any tips for removing exhaust manifolds on 242ss

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Any tips for removing exhaust manifolds on 242ss

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Old 10-23-2018, 05:48 PM
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Default Any tips for removing exhaust manifolds on 242ss

Trying to replace risers and manifolds on my 90 242ss. The manifold bolts are tough to get to because there isn’t much side clearance. Some of the bolts I can’t get a socket on because they are crusty but there isn’t any room to tap a socket onto the bolts. Looking to see if anyone has any tips. Really don’t want to pull the motor. I’ve gotten 5 bolts out so far but those were the ones with clean heads on them. Thanks in advance
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Old 10-23-2018, 05:51 PM
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Let the games begin. What are you planning going with for exhaust?
Good Luck, Really Good Luck. These are a Bitc? to work on.
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Old 10-23-2018, 06:33 PM
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Just doing stock replacements. Didn’t know when they were done last and I’m hoping I got to it in the nick of time saw some rust in both and some moisture in the heads so want to get it back together flush the oil and get it winterized
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Old 10-24-2018, 12:54 PM
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You may need to lift the motor up a few inches which isnt the time consuming if done correctly.
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Old 10-24-2018, 05:47 PM
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I was thinking about if I had to I’d possibly do that but hoping to figure it out in the boat. Hopefully can work on it this weekend and put it away until spring
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Old 10-24-2018, 06:43 PM
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You did remove the batteries and the "cabinetry", correct.
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Old 10-24-2018, 08:52 PM
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In some cases I have been forced to grind the bolt head off with a burr, then remove the bolt after the exhaust is off. Try heat and penetrating oil first and if possible, beat a socket that is too small ( may need to be metric) on the head. There isn’t much room to work so go slow and use a mirror. I went through all of this after I bought my boat, it’s a real good time. Best of luck.
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Old 10-24-2018, 09:18 PM
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What ever you do try not to shear bolt. Mine sheared and removal of head was required.
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Old 10-24-2018, 10:15 PM
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I didn’t remove the batteries as all the rear bolts came out easy. I haven’t removed the “cabinetry” as it was starting to get dark out but that may definitely help being able to lay down. Basically all the bolts that have come out came out pretty easy and all had never seize on them. Biggest issue is the crustiness on the heads of the bolts and not having room to tap a socket onto them. I will let you know how I make out after getting a chance to work on it again. Hopefully get some decent weather to work on it too
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Old 10-25-2018, 07:38 AM
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When you remove the cabinetry also remove the bar that holds the sliding doors and the front of the seat rests on. Now you can get to a lot more places than you thought. On the port side you mast likely will want to remove or loosen the power steering pump. When you get the manifolds off now would be an excellent time to replace all of the raw water hoses as you cannot do it with the exhaust on and I bet they are original to the boat

Last edited by GLENAMY 242SS; 10-25-2018 at 07:42 AM.
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