Mercruiser 8.1S Aluminum Exhaust Manifold Failures

Joined
Jul 7, 2007
Messages
18
I had to replace the risers, elbows, and aluminum exhaust manifolds on two 8.1S Mercruiser engines due to raw water intrusion in the manifolds. Fortunately it had just shown hints of leakage and the engines were fine. The total cost was over $5000.

Just this week I came across this thread which is worth reading if you have stock aluminum manifolds: http://www.clubsearay.com/forum/showthread.php?p=65805 Looks like Mercruiser is well aware of the problem...especially in a salt water environment.

The work was done by a Mercury authorized mechanic and based on the thread above I'm going to see if Mercruiser will make good on the expense. It's apparently a silent recall with no service bulletins.

Has anyone else had this problem, and did you receive any reimbursment from Mercruiser?
 

Bt Doctur

Supreme Mariner
Joined
Aug 29, 2004
Messages
19,346
Re: Mercruiser 8.1S Aluminum Exhaust Manifold Failures

Who would think that aluminum would corrode in salt water?
 

JustJason

Vice Admiral
Joined
Aug 27, 2007
Messages
5,321
Re: Mercruiser 8.1S Aluminum Exhaust Manifold Failures

Who would think that aluminum would corrode in salt water?

It does?????????

They should really start making them out of sodium. :D
 

gadget73

Petty Officer 1st Class
Joined
Jun 20, 2009
Messages
308
Re: Mercruiser 8.1S Aluminum Exhaust Manifold Failures

They raw water cool the aluminum manifold? Thats silly.
 
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