The other day I started on assembling the replacement parts for the muffler exhaust stacks. Cylinder #2 is easy enough but the redesign creates 3 pieces that make up stack #1 and the instructions with the original service bulletin no longer apply. Plans Chapter 48 was rewritten this month and leaves a little to be desired.
They have you torque down the exhaust nuts -- I had to order a metric crowsfoot kit -- after installing the top piece on cylinder #1 and tightening only until you see the first thread. But when you go back to install the lower two parts, you can't really get it all to fit unless you take off the top piece and even then, it's really tight. You put the nuts back on but they don't want you to torque them until the radiator goes on. But I had to tighten them enough to pull the piece into the cylinder slip joint. I sent pictures off to Van's support for their review. I don't care for the new system.
I reinstalled the springs and put a line of RTV on the front and back of each spring and in the clip to keep it from rotating and wearing.
Then I put the EGT probes in. There is very little slack in #1 and the instructions say to loosen and turn the bracket at the top to provide more slack, but turning it makes the probe interfere with other components, which the instructions specifically say don't allow to happen. I got the other three cylinders with enough slack, I think, but it was difficult.
I torqued down the probes on #2, #3, and #4 to 19 foot pounds -- 18 with the crowsfoot but I waited on #1 until I get the "all clear" from Van's on the installation.
I fit the bottom cowl to be sure the exhaust pipe fits through the hole and it's perfect!
