Manifold removal on a 2008 8.1s

rondds

rondds

Well-Known Member
Oct 3, 2006
8,859
Jersey Shore
Boat Info
2001 380DA
Engines
Merc 8.1s (2008)...Hurth ZF 63 V-drives...WB 7.0 BCGD (2013), Garmin 8208 & 740 MFDs, GMR 24xHD dome
I need to remove the right manifold of the starboard engine to get the generator out. Anyone know if the manifold can be removed along with the elbow as one unit?

If the elbow does need to come off, is part #15 below re-usable or must it be replaced - it is called a "Turbulator." I have a pretty extensive background with this type of work on Gen IV and Gen V 7.4s, but none with the 8.1s. "
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Ron, yes, you can leave the elbows on. But if you take them off, you can use the turbulators over. Don't try to remove #16, temp sensor, it's plastic and 2 out of 4 of mine broke when I replaced the manifolds and tried to remove them. Just unplug them from the harness if the manifolds are going back on the engne.
Have fun
 
Great info Mark. Thanks! I take it you did this on your 360DA?
 
"turbulator" to mercruiser looks like "exhaust restriction plate" to me.
 
Ron, I thought the turbulator was part #26. Anyway, I found that access to the outboard side was way easier if you take a feww minute to remove the muffler and some of the exhaust hose. Then you can lay down on the muffler platform and reach the outboard manifold bolts from the front of the engine. I guess you need to pull the muffler anyway to get the Gen out. Have fun! Mark
 
K...
There 's a fair amount of room to maneuver in this boat. The procedure of getting the manifold off isn't my big concern. Squeezing the gen out of the hole is!

Mark, I don't think the muffler will need to come out but we'll see. #26 is called a "resonator."
 
Ron, pay close attention to the turbulator, its my understanding that they are there to stop water from running back down the manifold under certain conditions...should be a regular inspection item as they will corrode away. Mike
 
I will just say this my marina pulled my Westerbeke out and naturally put it back. They did not have to remove any manifolds or risers in the process, and I have the item #20 risers on my engines. They did remove the rear cockpit transom seat and the rear section of the starboard side seat.
 
Mike...will do.

Rick...will probably photodoc the whole thing. Still not sure I'm disassembling the elbow from manifold during this task. Just interested in getting the gen out and new one in. Another day, another time.

Pseudo. That's interesting. Do you know if they pulled the muffler and slid the gen out the aft side? Man, I'd LOVE to know exactly how they pulled off that magic.

This is the view from directly above with the stbd seat and access hatch removed. The power hatch is closed in this pic. Gonna be tight and it's going to have to come out on an angle.

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I knew there would be a foot comment. No pedicure. DIY toenails.
 
If you take off the stern engine panel and seat, and the Exhaust hoses and engine cover bar, you should be able to remove the generator.
Take lots of pictures.
 
Mark
That's great stuff. Thanks a million!
RON
 
dc380 said:
If you take off the stern engine panel and seat, and the Exhaust hoses and engine cover bar, you should be able to remove the generator.
Take lots of pictures.
Click to expand...

This is what I believe they did, they also disconnected the engine hatch lifting rod from the cylinder and tied it back, the hatch cover flush against the transom.
 
Ron,

Let me know when you want to do the job - I'll come down and do it with you.

Dale
 
God love ya Dale! It's scheduled for Friday Sept 20 at Vince's house (Ryker Bella). Don't take a day off from work for this. Unless you really want to!
 
So, I get to work on a boat, and take a day off????? HHHmmmmm, let me think about that.......

OK, I'll do it, but only if your bilge is cleaned by then - I don't want to get dirty

Dale
 
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