Leaking Corsa captains call exhaust repair

[paulswagelock]

So I noticed a small drip at the end of the season from my Corsa exhaust, where the shaft exits the diverter tube. It dripped about once every 45 seconds or so, very little. I called Corsa and they recommended changing the o rings that seal the shaft in the the diverted tube. They sent me a bag of free replacement o rings, maybe 1/4" or so. Today I went to my storage building and dug in. Six large hose clamps and one electrical plug hold it in there. A cordless drill and flat bit made quick work of the clamps. With some wiggling, wrangling and brute force I got the diverted assembly out from the 3 large hoses it mounts to. I left the hoses connected in the boat and removed them all from the diverted itself. Once on the bench I could see the butterfly plate that needed removed to allow the shaft to slide out. I left all the linkages connected and simply removed the two hex head screws holding the entire actuator assembly to the diverted. This avoids any adjustment later. The hex head screws holding the butterfly plate were fairly deep inside, so a combination of an Allen bit, some extensions, and a ratcheting screwdriver got them out. Make sure you take a picture of the linkage before you unbolt the bracket so you see how to put it back. It can swivel and go back two different ways, but only one is correct. The small o rings get cut out then you roll the two new ones down the shaft into their recess slots. Then reverse the process to get it back together. Some tape to hold the butterfly Allen screws to the long extension is needed to get them started. Once together, compress the actuator manually to make sure it all moves freely. Then wrestle the entire assembly back in, bottom hose on first, then side hose to through hull fitting, finally last hose to manifold assembly.
Tighten 6 hose clamps, plug in electrical connector, done.

Took about 1 hour. On a scale of 1 to five, one being easy, this is a 2.