[C320-list] Yanmar exhaust architecture
clburti at gmail.com
clburti at gmail.com
Sun Oct 19 18:24:38 PDT 2014
Danny this would make a good Mainsheet article if you could supply a few hi resolution photos directly to me by email.
Fair Winds
Chris Burti
Commitment
Catalina 320, #867
From: Millers
Sent: Sunday, October 19, 2014 7:47 PM
To: 320
Thanks Danny, good information. I printed your comments for reference.
Art
Sent from my iPhone
> On Oct 19, 2014, at 5:05 PM, "danny jensen" <danny at jensenshouse.com> wrote:
>
> Art,
> Here is a repost of my project. Yes the riser was in good condition it was $130 but I replaced it anyway because freeing it from the elbow may have been troublesome. Maybe I could have done this from home on a bench vise but it could have stressed the old part??
>
>
> Here are the details of my mixing elbow / aqua lift muffler replacement project.
>
> I have about 500 hours on a 2004 C320 with a Yanmar 3GM30F-YEU. The mechanic recommended I change the mixing elbow in the next 12 months. The U Mixing Elbow inside was corroded at the point where the raw cool raw water mixes with exhaust. The riser appeared to be in good shape but the two parts looked to be bonded together and my mechanic told me to replace the entire assembly Elbow, riser and join. I read several owners accounts of failed mixing elbows and mufflers / muffler repairs. The lead time to get a muffler from Catalina was estimated to be 2 months. The general consensus was to replace the muffler after about 10 years. Mufflers seem to fail mostly near the screw holes in the corners. Some owners think this is due to vibration from the engine exhaust hose. I used Jeff Hares rule and decided to replace the muffler on my schedule instead of the boats schedule especially because of the 2 month lead time for the muffler. The cost of the muffler from Catalina was $374.
>
> I contacted Ken Roy at Catalina and gave him my hull number and some pictures and dimensions of my existing muffler (it is for sale now). Ken asked for some more dimensions. Ken sent me back a picture of the muffler he proposed to make for me and requested payment. It took about 2 months total to get the muffler.
> I ordered the gasket, mixing elbow, SS joint and riser exhaust from Bayshore Marine(see below). Next, I considered the muffler vibration issue. Some owners felt that a hump hose would isolate the vibration from the engine to the muffler. The existing wet exhaust hose connecting mixing elbow to muffler input was a 22 inch 2 in. id. I decided replace with 2 hose segments of more flexible trident corrugated exhaust hose joined together with an exhaust hump hose I purchased from Catalina Direct.
>
> Here are the details. The procedure took about 3.5 hours including driving home once.
>
> 1. I turned off the raw water thru hull, disconnected the 3/8 hose connection at the elbow, the 4 riser exhaust bolts came off with no problem. Then I disconnected the elbow from the 2 in. exhaust hose. I used a radiator hose pick to remove the hoses. They came right off with no problem. Don’t sweat removing the hoses.
>
> 2. I took the old elbow assembly home where I used it for reference to create the new assembly using a vise. I don’t believe you can create the new assembly without the help of a vise and 2 large adjustable 15 in wrenches. Don’t try to make the new assembly on your boat! You will need to twist the 3/8 in input 180 degrees then you will need to create the exact same angle as the old elbow by threading the joint into the elbow and exhaust riser. I used high temperature anti seize on the joint threads before assembly.
>
> 3. I used a gasket scraper to easily remove the old gasket. Then I applied some high temp gasket seating material to both sides of the new gasket and bolted the elbow assembly to the motor.
>
> 4. I removed the 4 stainless screws securing the muffler to the boat and I removed the output exhaust hose from the old muffler using the radiator hose pick. The hoses come off the muffler without any problem. The muffler comes out of the boat without any problem.
>
> 5. I put the new muffler in place and connected the output exhaust hose without any issues. I found the screw holes on the new muffler did not match the screw holes on the muffler. I could get the 2 screw holes forward to line up but then the aft screw holes with not align with the existing holes. Access to the forward inboard screw is somewhat limited so you will want to match the forward inboard screw with the existing hole then use a drill motor to self tap new holes with the muffler in place. The existing self tapping screws were in good shape and I did not need to drill pilot holes, I just drove the screws into the glass with the muffler in place after I screwed down the forward screws. Apply a good amount of silicon grease to the muffler drain.
>
> 6. I used a sawzall to cut an 8 in and 13 in segment of corrugated exhaust hose then I joined them with a hump hose using double hose clamps on each side of the hump hose. Then I connected the hose to the mixing elbow and the input side of the muffler.
>
> 7. I turned on the thru hull and ran the engine. White fiberglass chips from the new muffler were spitting out the exhaust for a while. No leaks. The hump hose appeared to do the job limiting vibration. I left the rear engine cover off and took the boat out in open water and ran the motor up 3000 RPM. I went below and to my surprise I saw smoke coming from the exhaust riser side of the stainless steel joint nut! No water. It appeared that the joint was oozing and burning anti-seize. After about 10 minutes this smoking stopped. I’m assuming this is normal but it spooked me. I’m going to put a co2 monitor in the aft cabin to make sure I don’t have gas leaks.
>
> -----Original Message-----
> From: C320-list [mailto:c320-list-bounces at lists.catalina320.com] On Behalf Of millers1 at aol.com
> Sent: Sunday, October 19, 2014 3:58 AM
> To: C320-List at Catalina320.com
> Subject: Re: [C320-list] Yanmar exhaust architecture
>
>
> Danny, Thanks for providing a comprhensive list for the job.
> When you removed the Riser Exhaust part, what was it's condition??
> The Elbow is always a mess, but I find the Riser to be in pretty
> good condition usally.
> Art #680
>
>
> -----Original Message-----
> From: danny jensen <danny at jensenshouse.com>
> To: C320-List <C320-List at Catalina320.com>
> Sent: Sat, Oct 18, 2014 6:55 pm
> Subject: Re: [C320-list] Yanmar exhaust architecture
>
>
> I have a yanmar 3GM30F-YEU. HULL 972. ALSO NOTE THE HOSE I USED WAS SOMEWHAT
> FLEXIBLE. BAYSHORE MARINE IS AN EXCELLENT SOURCE FOR YANMAR PARTS.
>
> Parts:
> bayshore marine:
> 128370-13201 gasket $4.92
> 124070-13520 U mixing elbow $169.33
> 128370-13610 riser exhaust $130.39
> 104214-13580 joint =09=09$28.79
> Note:
> 27233-250000 plug comes with 124070-13610
> 124070-13300 elbow 3/8 comes with 124070-13610
>
> Parts from Catalina Yachts (Ken at catalinayachts.com)
> 1 Muffler $374 plus Shipping
>
> Parts from Catalina direct:
> High Temp Anti-Seize Compound (#Z2858): 1 Item Total: $15.95 Exhaust Hump Hose
> 1-5/8"I.D X 6" (#Z2152): 1 Item Total: $31.49
>
> Tools Harbor Freight
> 8" Radiator Hose Pick $3.99
> Carbon/Gasket Scraper $2.99
> High Temp Gasket seating compound
>
> MMI Marine
> TRI252-2004
> TRIDENT CORRUGATED FLEX SAE J2006 MARINE WET EXHAUST HOSE (HARD WALL WITH W=
> IRE) - 2 Feet $15.00
> BUA70HSS36C
> BUCK HOSE CLAMPS S/S FROM 1 13/16" TO 2 3/4"=094 $8.00
>
> DANNY
>
> -----Original Message-----
> From: C320-list [mailto:c320-list-bounces at lists.catalina320.com] On Behalf Of
> danny jensen
> Sent: Friday, October 17, 2014 8:55 AM
> To: C320-List at Catalina320.com
> Subject: Re: [C320-list] Yanmar exhaust architecture
>
> New designs could be dangerous because you don't want back flow pressure from
> the muffler to the engine. Search on internet for bad stories of serious engine
> damage. Use a hump hose and consider mounting muffler on thin rubber matting.
> Replace the muffler every 8-10 years and you should be finished with your
> muffler woes.
> Danny
> #972
>
> Sent from my iPhone
>
>> On Oct 17, 2014, at 6:14 AM, "colloua5 at aol.com" <colloua5 at aol.com> wrote:
>>
>>
>>
>>
>> These part numbers are they from yamar direct ?
>>
>>
>> Thanks for all the info
>>
>>
>> on another note .....my muffler box failed, I am going to clean it, re-epoxy
> the joint where the two meet and then fiberglass mesh the two together on the
> outside completing the sealed unit. From what I read the new units seem as
> poorly designed as the original.
>>
>>
>> I am contemplating having one made of brass with soldered joints over the
> winter, pressure test it and install, the cost should be equivalent to the
> fiberglass replacement unit
>>
>>
>>
>>
>>
>>
>> -----Original Message-----
>> From: tharrison <tharrison at innovations-plus.com>
>> To: C320-List <C320-List at Catalina320.com>
>> Sent: Thu, Oct 16, 2014 11:09 am
>> Subject: Re: [C320-list] Yanmar exhaust architecture
>>
>>
>> One item to note is hose size. Mine was 1 5/8.
>>
>> There is a reverse direction joint between the elbow and mixing elbow. Play
> with
>> this piece and the final orientation.
>>
>> 124070-13520 mixing elbow
>> 128370-13610 elbow
>> 104214-13580 joint
>>
>> Gasket, I do not have this part number.
>>
>> High temp gasket seal - red from NaPa
>>
>> Some anti seize compound for on the joint threads.
>>
>> That is all I can thing about.
>>
>> Others please verify the part numbers. I fairly sure.
>>
>> Sent from my iPhone
>>
>>> On Oct 16, 2014, at 6:53 AM, Graeme Clark <cg at skyflyer.co.uk> wrote:
>>>
>>> Timothy
>>>
>>> Thats exactly why I wanted a photo or diagram (or even part numbers) , so I
>> can get an idea of how the thing is put together following what would appear
> to
>> be an early experiment on mine!
>>>
>>> For example at what point of the exhast doe sthe water injection take place?
>> Itr seems to me that the cooling water exits on the port sode of the engine
> and
>> the exhaust on the starboard side, so some form of connection needs to be made
>
>> between the two. The ‘standard’ Yanmar exhast injection elbow has the water
>> entering the exhaust just a few inches from the engine block, i.e., really
>> early; mine has the water enetering about 18 inches downstream, hence,
>> presumably the need to lag the prt beforehand which receives no cooling
> effect!
>>>
>>> Regards
>>>
>>> Graeme
>>>
>>>
>>>
>>> Message: 7
>>> Date: Tue, 14 Oct 2014 20:27:53 -0400
>>> From: Timothy Osburn <tosburn1958 at gmail.com>
>>> To: C320-List at catalina320.com
>>> Subject: Re: [C320-list] Yanmar exhaust architecture
>>> Message-ID:
>>> <CAJEc2k1MKDpjndsjfeZcPNCAAC3xWk0nXZoogQ=6dBmdvtE6ww at mail.gmail.com>
>>> Content-Type: text/plain; charset=UTF-8
>>>
>>> I just had mine replaced last month and the mechanic was able to use off
>>> the shelf parts. I have the same engine.
>>>> On Oct 14, 2014 5:37 PM, "Graeme Clark" <cg at skyflyer.co.uk> wrote:
>>>>
>>>> I have just transitioned from one/third shared ownership of hull #303 with
>>>> a Westerbeke to sole ownership of hull # 366 which (I have been told) is
>>>> one of the very first to be fitted with a Yanmar 3GM30F engine.
>>>>
>>>> The exhaust arrangement/architecture is very different from the Westerbeke
>>>> and I wondered if this was now ?standard? in all Yanmar engined 320s or has
>>>> it been superseded with something else?
>>>>
>>>> The exhaust is on the starboard side of the engine, so there is a length
>>>> of lagged exhaust pipe as per this photo
>>>>
>>>> http://i59.tinypic.com/244tch3.jpg
>>>>
>>>> which then connects to a section on the port side where the water is
>>>> injected. The entire assembly looks a bit ?home made?!
>>>>
>>>> If I have to replace the exhaust ?elbow? (in reality not an elbow at all)
>>>> where do I get this piece or is it custom made by a fabricator.
>>>>
>>>> If anyone else with a 3GM30F has a photo or diagram of the exhaust
>>>> arrangement I?d be most grateful
>>>>
>>>> Many thanks
>>>>
>>>> Graeme,
>>>> Britain
>
>
>
>
>
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