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GASOLINE ENGINE 8.1S INBOARD MODELS
INSTALLATION MANUAL
After Completing Installation, These Instructions Should Be Placed With The Product For The
Owner's Future Use.
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information
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Notice to Installer
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Quicksilver Products
Lubricants / Sealants / Adhesives
Torque Specifications
Serial Number Decal Placement
Engine Rotation
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Transmissions
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Velvet Drive Transmissions
ZF / Hurth Transmissions
Propeller Rotation
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Installation Requirements
Engine Bed
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Engine Compartment
Exhaust System
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Fuel Delivery System
Battery
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EFI Electrical System Precautions
Instrumentation
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Propeller Selection
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Throttle/Shift Remote Control and Cables
Seawater Connections
Hot Water Heater
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90-863080002 JANUARY 2001
NOTICE to INSTALLER
NOTICE to COMMISSIONING DEALER
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Printed in U.S.A. - 2001, Mercury Marine
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Engine Installation
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Engine Oil Dipstick Location
3
Battery Cable Connection
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Engine Mount Pre-Adjustment
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Initial Engine Alignment
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Final Engine Alignment
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Engine Connections
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Seawater Pickup Pump Connection
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Fuel Supply Connection
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Audio Warning System Connection
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Electrical Connections
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Exhaust System
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Shaft Log Seal Connection
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Shift Cable Installation And Adjustment
Velvet Drive Transmissions
- 5000 Series
Velvet Drive Transmissions - 72C In-Line
Hurth Transmissions
Predelivery Preparation
Battery Connection
Test Running Engine
Boat In The Water Tests
Cold Weather and
Extended Storage Draining
Coolant And Water Flow Diagrams
Predelivery Inspection
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser,
Mercury,
Mercury
Quicksilver, RideGuide and MMPP.
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Summary of Contents for Mercury MerCruiser 8.1S
- Page 1 ..Predelivery Inspection ....Printed in U.S.A. - 2001, Mercury Marine 90-863080002 JANUARY 2001 Page 1 of 58...
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Page 2: General Information
IMPORTANT: Indicates information or instructions that are necessary for proper in- stallation and/or operation. This installation manual has been written and published by Mercury Marine to aid the boat manufacturer involved in the application and installation of the products described herein. -
Page 3: Quicksilver Products
GASOLINE ENGINE 8.1 S INBOARD MODELS Quicksilver Products Quicksilver gauges, remote controls, steering systems, propeller shaft couplers, and other accessories are available for this product. Refer to Mercury Precision Parts/Quicksilver Accessories Guide for complete listing. This Guide is available from:... -
Page 4: Serial Number Decal Placement
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Serial Number Decal Placement There are three engine serial number decal strips provided with each power package. One should be used for each of the following: • Engine Specification Decal • Warranty Registration Card •... -
Page 5: Zf / Hurth Transmissions
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS On Velvet Drive 72C Transmissions the gear ratio (in forward gear) is marked on transmission identification plate. Transmission output shaft rotation and propeller rotation required (in forward gear) is indicated on a decal on transmission case. Transmission rotation is described when viewed from the rear of transmission. -
Page 6: Propeller Rotation
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Propeller Rotation Propeller rotation is not necessarily the same as engine rotation. Refer to the appropriate following information and drawings for specific information. These transmissions are full power reversing transmissions, allowing a standard, LH rotation engine to be used for both propeller rotations. - Page 7 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Propeller Rotation (Continued) 25506 ZF / Hurth 630A or 800A - 8° Down-Angle Transmissions 72959 72959 ZF / Hurth 630V - V-Drive Transmissions Direction Of Shift Lever Engagement (Toward Flywheel) Engine/Transmission Input Shaft Rotation Direction (LH) Transmission Output/Propeller Shaft Rotation Direction (LH) Direction Of Shift Lever Engagement (Away From Flywheel) Transmission Output/Propeller Shaft Rotation Direction (RH)
- Page 8 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS APPLICATION / RATIO SELECTION The propeller shaft speed is determined by engine speed and the transmission ratio. Every boat has a best shaft speed that directly relates to boat speed. If propeller shaft speeds are too high an inordinately small propeller must be used resulting in poor performance.
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Page 9: Installation Requirements
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Installation Requirements Engine Bed Distance between starboard and port engine mount is 22-1/2 in. (572 mm). Engine bed must position engine so that a minimum of 1/4 in. (6 mm) up and down adjustment still exists on all 4 mounts after performing final engine alignment. - Page 10 +20° to +176° F (–7° to +80° C) without failure.” Carburetors, throttle body injection (TBI) units and components for multi-port EFI systems used by Mercury MerCruiser meet this specification. Under the hottest outside air temperature condition at which the boat will be operated, the air temperature inside the engine compartment, measured at the flame arrestor, should not exceed 176°...
- Page 11 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS TESTING NOTE: The boat being tested shall be a standard production boat fitted as it would be for delivery to a dealer. NOTE: Temperature test meter used shall be of the type that can be read without opening the engine cover.
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Page 12: Exhaust System
Improper installation may allow wa- ter to enter the exhaust manifolds and combustion chambers and severely damage the engine. Damage caused by water in the engine will not be covered by Mercury MerCruiser Warranty, unless this damage is the result of defective parts. -
Page 13: Down-Angle Fore End
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Continuous Downward Slope From Horizontal Engine Model Minimum Maximum Installation Angle* Down-Angle Fore End 2-5/16 in. (59 mm) 4-5/8 in. (117 mm) 11° 21° Inboard Raised 2° per 12 in. (305 mm) per 12 in. (305 mm) Down-Angle Fore End 2-3/4 in. - Page 14 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS • The exhaust resonator is positioned with the inside flat surface at the preferred distance of 17 in. (432 mm) from the front edge of the exhaust hose but no closer than 2 in. (51 mm) to the exhaust outlet on sterndrives.
- Page 15 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS NOTE: A kit is available, when applicable, to reduce from the 4 in. (102 mm) to 3 in. (76 mm). Refer to the Quicksilver Accessories Guide, for kit part number. 71774 Typical Continuously Sloping Exhaust Line Exhaust Elbow Exhaust Hose Or Pipe Muffler (If Equipped)
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Page 16: Fuel Delivery System
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Fuel Delivery System WARNING Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when installing fuel delivery system. The main concern of a boat’s fuel system is safety; this must be achieved through a technically sound installation and constant inspection. - Page 17 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Diameter of fittings and lines must not be smaller than 3/8 in. (10 mm) I.D. on 496 cid / 8.1L engines. 5. On Multi-Engine Installations: It is best to use a fuel pickup and supply line for each engine.
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Page 18: Battery
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Battery IMPORTANT: Boating industry standards (BIA, ABYC), federal standards and Coast Guard regulations must be adhered to when installing a battery. Be sure the battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. - Page 19 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Battery Isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose. NOTE: Sure Power Industries Inc.
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Page 20: Efi Electrical System Precautions
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS EFI Electrical System Precautions NOTE: All references to EFI models apply to EFI and MPI Engines. The following precau- tions apply to all EFI models. CAUTION Avoid damage to the EFI electrical system and components. Refer to the following precautions when working on or around the EFI electrical harness or when adding other electrical accessories: •... -
Page 21: Propeller Selection
Refer to Quicksilver publication - Everything You Need To Know About Propellers P/N 90-8614492. Specified engine WOT and operating rpm range are listed in the Mercury MerCruiser Operation, Maintenance and Warranty Manual attached to the engine. -
Page 22: Throttle/Shift Remote Control And Cables
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Throttle/Shift Remote Control and Cables CAUTION Remote control and shift cable must position transmission shift lever exactly as shown or transmission failure may occur. Do not remove poppet ball or spring. Damage caused to transmission as a result of improper shift lever positioning will not be covered by warranty. -
Page 23: Hot Water Heater
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Hot Water Heater IMPORTANT: When connecting a cabin heater or hot water heater, certain require- ments must be met, including, but not limited to the following: • Supply hose (from engine to heater) and return hose (from heater to engine) MUST NOT EXCEED 5/8 in. -
Page 24: Engine Installation
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Engine Installation NOTICE to INSTALLER Before Starting Installation read General Information and Installation Require- ments completely. Engine Oil Dipstick Location Engine crankcase oil dipstick can be located on either starboard or port side of engine to suit installation requirements. -
Page 25: Engine Mount Pre-Adjustment
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Engine Mount Pre-Adjustment CAUTION Engine compartment size may require the removal of additional components. 1. Remove engine cover. 2. Remove hardware holding engine to shipping pallet. Attach a suitable sling to lifting eyes on engine. -
Page 26: Initial Engine Alignment
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 5. Loosen clamping bolts and nuts on all 4 engine mount brackets to ensure the following: • Large diameter of mount trunnion extended as shown. • Each mount base is downward. Tighten clamping bolts and nuts slightly to prevent mov- ing in or out. - Page 27 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS MODELS WITH 8° DOWN ANGLE TRANSMISSIONS - VELVET DRIVE OR ZF / HURTH 1. Lift engine into boat and position on engine bed so that transmission output flange and propeller shaft coupler are visibly aligned (no visible gap seen between coupling faces when butted together).
- Page 28 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS MODELS WITH V-DRIVE TRANSMISSIONS 1. Lift engine into boat and position so that enough propeller shaft protrudes through transmission and output flange for propeller shaft coupler to be attached. Then install coupler and position engine (no visible gap between coupling faces when butted together).
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Page 29: Final Engine Alignment
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Final Engine Alignment CAUTION To avoid vibration, noise and damage to transmission output shaft oil seal and bearings, engine must be properly aligned. IMPORTANT: Engine alignment MUST BE RECHECKED with boat in the water, fuel tanks filled and with a normal load on board. - Page 30 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 3. Ensure that coupling centerlines align by butting propeller shaft coupler against transmission output flange. Shoulder on propeller shaft coupler should engage recess on transmission output flange face with no resistance. 72597 Incorrect Correct NOTE: Some propeller shaft couplers may not have a shoulder on mating face.
- Page 31 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 4. Check for angular misalignment by hand holding coupling faces tightly together and checking for a gap between coupling faces with a .003 in. (0.07 mm) feeler gauge at 90° intervals. 75534 Velvet Drive 50608 50609 ZF / Hurth...
- Page 32 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 5. If coupling centerlines are not aligned or if coupling faces are more than .003 in. (0.07 mm) out of parallel, adjust engine mounts. a. TO ADJUST ENGINE UP OR DOWN: Loosen locking nut on mounts requiring adjustment and turn adjusting nuts in desired direction to raise or lower.
- Page 33 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 9. Bend one of the tabs on the tab washer down onto the flat of the adjusting nut. 70057 Clamping Bolts And Nuts Locknuts On All 4 Mounts Tab On Tab Washer Measurement - 1-3/4 in. (45 mm) Or Less IMPORTANT: All coupler bolts must be SAE Grade 8 (Metric Grade 10.9) or better, with a shoulder (grip length) sufficient to pass through the mating face plane of the couplers.
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Page 34: Engine Connections
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Engine Connections Seawater Pickup Pump Connection 1. Remove shipping cap and connect seawater inlet hose to the upper fitting. 77512 Seawater Inlet Hose Attached To Upper Fitting Fuel Supply Connection A flexible fuel line must be used to connect fuel line to engine to absorb deflection when engine is running. -
Page 35: Audio Warning System Connection
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Audio Warning System Connection WARNING Alarm is not external ignition-proof, therefore, DO NOT mount alarm in engine or fuel tank compartments. 1. Select a location for audio warning alarm which meets all of the following: •... -
Page 36: Electrical Connections
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Electrical Connections 1. Connect the instrumentation wiring harness to engine harness plug at location shown. 76938 Engine Harness Plug 2. Coat both battery cable terminals with Quicksilver Liquid Neoprene. After liquid neoprene has dried, slide rubber boot over positive cable connection. 74503 74660 Negative (BLK) Battery Cable... -
Page 37: Exhaust System
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Exhaust System CAUTION Avoid exhaust hose failure. Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots which could eventually result in burned-through exhaust hoses. Exhaust hoses and/or tubes must be cor- rectly connected to exhaust elbows so that they do not restrict the flow of discharge water from exhaust elbow. -
Page 38: Shaft Log Seal Connection
Avoid engine overheating which could result in engine damage. Damaged caused by improper cooling system connections for the propeller shaft log seal IS NOT cov- ered by the Mercury MerCruiser limited warranty. IMPORTANT: Reducer fitting has been carefully sized to maintain the proper pressure balance in the cooling system and must NOT be removed. -
Page 39: Shift Cable Installation And Adjustment
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Shift Cable Installation And Adjustment IMPORTANT: When installing shift cables, be sure that cables are routed in such a way as to avoid contact with moving parts and/or sharp bends. All bends must make greater than an 8 inch (203 mm) radius. - Page 40 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS CONNECT AND ADJUST QUICKSILVER SHIFT CABLES 1. Be certain anchor stud is installed in the front hole. 73284 Shift Cable Bracket Anchor Stud In Front Hole 2. Place remote control shift lever and transmission shift lever in NEUTRAL position. 3.
- Page 41 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS CAUTION Transmission failure may occur. Velvet Drive Transmission Warranty is jeopardized if the shift lever poppet ball or spring is permanently removed, if the shift lever is repositioned or changed in any manner or if remote control and shift cable do not position shift lever exactly as shown.
- Page 42 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 12. If proper positioning is still not obtained, remote control does not provide sufficient shift cable travel and must be replaced. 73587 Typical ZF / Hurth Transmission Shown Shift Lever Shift Cable Bracket 13.
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Page 43: Velvet Drive Transmissions - 72C In-Line
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 71897 50073 Typical Dual Cable Installation - Rear Approach Cable End Guide Spacer (As Required) Elastic Stop Nut And Washer Bushings Cable Barrel Location Cable Barrel Stud Cable End Guide Stud Velvet Drive Transmissions - 72C In-Line IMPORTANT: Velvet Drive Transmission Warranty is jeopardized if the shift lever pop- pet ball or spring is permanently removed, if the shift lever is repositioned or changed in any manner or if remote control and cable do not position shift lever correctly. - Page 44 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 1. Verify shift cable stud is in appropriate stud hole as indicated. Tighten elastic stop nut securely. 50947 8.1L Shift Cable Anchor Stud Hole 2. Place remote control shift lever and transmission shift lever in neutral position. 3.
- Page 45 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 11. If transmission shift lever is still not positioned properly for both gears, move anchor stud on shift cable bracket to another hole and recheck shift cable position. 12. If proper positioning is still not obtained, remote control does not provide sufficient shift cable travel and must be replaced.
- Page 46 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 50946 Front Entry Single Station Installation In-Line And V-Drive 50946 Front Entry Dual Station Installation In-Line And V-Drive Cable End Guide Cable Barrel Cable Barrel Stud Elastic Stop Nut And Washer Spacer Cable End Guide Stud Elastic Stop Nut And Washer NOTE: For models equipped with a dual station shift bracket such as the one shown, refer to shift cable manufacturer’s instructions for adjusting the cable.
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Page 47: Hurth Transmissions
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Hurth Transmissions - HSW 630A, 630V, 800A ZF / IMPORTANT: These Hurth transmissions are full reversing transmissions. Direction of output/propeller rotation is determined by hookup of shift cable at remote control. Shift cable must be hooked up to remote control before starting installation and adjustment procedures. - Page 48 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS a. Check that remote control is in neutral position. b. Push in on control cable end with enough pressure to remove play, and mark position “a” on tube. c. Pull out on control cable end with enough pressure to remove play, and mark position “b”...
- Page 49 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 10. If transmission shift lever will not position properly in both gears, move transmission shift lever stud to the other hole and recheck shift cable position. 11. If transmission shift lever is still not positioned properly for both gears, move anchor stud on shift cable bracket to another hole and recheck shift cable position.
- Page 50 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 73589 71210 Typical Single Cable - Forward Entry Cable End Guide Locknut and Washer Spacer (Fits Over Bushings) Bushings Cable Barrel Location Spacer (Fits Over Stud) Cable Barrel Stud Cable End Guide Stud 50229 73587 Typical Single Cable - Rear Entry...
- Page 51 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 73590 71211 Typical Dual Cable - Forward Entry Cable End Guides Locknut And Washer Spacer (Fits Over Stud) Bushings Cable Barrel Locations Cable Barrel Stud Cable End Guide Stud 73591 50073 Typical Dual Cable - Rear Entry Cable End Guides Locknut And Washer Spacer (Fits Over Stud)
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Page 52: Predelivery Preparation
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Predelivery Preparation NOTICE Before starting Predelivery read General Information and Installation Require- ments completely. Battery Connection IMPORTANT: Engine electrical system is negative (–) ground. 1. Connect engine POSITIVE (+) battery cable (usually RED) to POSITIVE (+) battery terminal. -
Page 53: Cold Weather And Extended Storage Draining
Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION If engine will be exposed to freezing temperatures, ensure closed cooling section is filled with an ethylene glycol antifreeze and water solution properly mixed to pro- tect engine to lowest temperature to which it will be exposed. - Page 54 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS 3. Install air pump on the actuator fitting. 77638 77516 Actuator Fitting Green Indicators Manual Release Valve Air Pump Lever 4. Pull lever on air pump up (vertical) to lock pump on actuator fitting. 5.
- Page 55 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS MANUAL DRAIN SYSTEM NOTE: If air actuated drain system fails, use the blue drain plugs to drain engine. NOTE: It may be necessary to lift, bend or lower hoses to allow water to drain completely when hoses are disconnected.
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Page 56: Coolant And Water Flow Diagrams
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Coolant And Water Flow Diagrams NOTE: Certain components in the following diagram may look different than on your particular power package, but the water and coolant flow paths remain similar on all engines. Page 56 of 58... - Page 57 INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Seapump Air Actuator Transmission Cooler Oil Cooler Fuel Cooler Air Actuator Heat Exchanger Thermostat Crossover 10 - Water Circulating Pump 11 - Coolant Reservoir 12 - Exhaust Manifold 13 - Elbow 14 - Water And Exhaust Outlet Seawater Coolant...
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Page 58: Predelivery Inspection
INDEX GASOLINE ENGINE 8.1 S INBOARD MODELS Predelivery Inspection Check/ Check/ Applicable Adjust Applicable Adjust CHECK BEFORE RUNNING ON THE WATER TEST Drain plug in and petcocks Engine alignment (Inboards only) closed Seawater inlet valve open Starter neutral safety switch operation Engine mounts tight Water pump operation Engine alignment...
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