Merc 496 water drain delete
 

As with many, my 2002 496 Mag HO water drains were leaking. I decided to delete them, I was surprised to find no kits, and little information for doing so. Here is what I did.

Port side of the engine, heat exchanger to cool fuel system. I removed the drain actuator and replaced it with 6" of 1 1/4" heater hose, coupled to the hose from the exchanger with a merc 1 1/4" drain #861505A. Be sure to support the hose, I used a large zip tie to one of the studs the actuator was attached with.

Starboard side of the engine, water pump intake and output hoses. I removed the drain actuator. I Replaced the upper intake 1 1/4" hose with a 26" wire reinforced 1 1/4" hose to my flush T from the water pump. Be sure to support the hose. I used a large zip tie to my offshore mounts. I replaced the lower output hose with 12" of 2 1/2" heater hose to a 2 1/2" barbed billet aluminum splice (fresh water, salt should use stainless) connected to the 2 1/2" hose after the removed actuator. All connections double clamped, except at the water pump.

Make sure hoses are secured in a way they can't rub on the actuator studs or hose clamps, (or anything else).

Got any pictures of all your work?

I'm removing my water pump drain actuator in the fall. But I'm just replacing the existing backing plate with a standard Merc non air fittings one.

My pics didn't come out well. I had the seperate actuator, not part of the water pump. It was all pretty easy. I will see if I can get decent pics.

Anyone who counts on that drain system to winterize their engine might be in for an expensive surprise in the spring. It cost me a heat exchanger.

https://cimg2.ibsrv.net/gimg/www.off...b4342b0f2.jpeg
Here is the delete kit.

Along this line, I wounder if anyone has ever replaced the Gen 7 pump to the Gen 4 pump.
The is slightly taller and more narrow then the Gen 2 and 4

Bravo Gen 2 & 4 pumps 47-59362T1
Length 2.75 OD 2.63 Width 2.01 Jabsco 17954-0001
Bravo Gen 7 pump 47-8M0104229 (old 47-862232A2)
Length 2.50 OD 2.50 Width 2.25

Main reason to thing about it is the cost of the rebuild parts. $100 for the 2 & 4 which includes the housing