Merc 496 water drain delete
07-14-2020 | 07:49 PM
#1
Thread Starter
Charter Member #1055/Moderator
Joined: Feb 2001
Posts: 4,585
Likes: 0
From: CNY
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).
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).
07-27-2020 | 07:00 PM
#3
Thread Starter
Charter Member #1055/Moderator
Joined: Feb 2001
Posts: 4,585
Likes: 0
From: CNY
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.
__________________
[img][/img]
[img][/img]
07-28-2020 | 09:13 AM
#5
Offshoreonly Advertiser
Joined: Oct 2002
Posts: 1,365
Likes: 34
From: De.
Here is the delete kit.
__________________
www.diamondperformanceparts.com
[email protected]
http://www.facebook.com/pages/Diamon...07878772615803
302-521-0123
The Best Parts & Service At The Best Price
www.diamondperformanceparts.com
[email protected]
http://www.facebook.com/pages/Diamon...07878772615803
302-521-0123
The Best Parts & Service At The Best Price
07-28-2020 | 09:43 AM
#6
Registered
Joined: Nov 2009
Posts: 4,198
Likes: 500
From: KY
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
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
