Mercury MerCruiser OEM 8-Piece Intake Manifold Gasket Set 805522A1 | 7.4L 8.2L 454 502 MPI EFI Gen V Gen VI

Mercury MerCruiser OEM 8-Piece Intake Manifold Gasket Set — Part 805522A1

• Part Number: 805522A1
• Full Catalog Number: 27-805522A1
• Brand: Mercury Marine / MerCruiser (Genuine OEM)
• Official Product Type: Engine Gaskets — Intake Manifold & Plenum Gasket Set
• System: Intake system — intake manifold and intake plenum sealing
• Kit Contents: 8 gaskets — intake manifold and intake plenum gaskets for applicable 7.4L and 8.2L MPI engine service
• Application: MerCruiser 7.4L / 454 CID and 8.2L / 502 CID MPI sterndrive and MIE inboard engines — Gen V and Gen VI
• Coverage: 1996–2001 7.4L and 8.2L MPI applications (verify by engine serial number)
• GTIN / UPC: 745061279506
• Weight: approx. 0.2 kg

Intake manifold and plenum set — not a full engine overhaul kit: 805522A1 is specifically an intake manifold and plenum gasket set for MPI / EFI 7.4L and 8.2L MerCruiser big-block engines. It is not a full engine rebuild or head gasket set. Gen V and Gen VI production differences mean the engine serial number should be used to confirm the intake diagram calls for 805522A1 before ordering.

What It Is

The 805522A1 / 27-805522A1 is the genuine OEM 8-piece intake manifold gasket set used for intake manifold and intake plenum service on selected MerCruiser 7.4L / 454 CID and 8.2L / 502 CID MPI marine engines. It covers both Gen V and Gen VI big-block intake manifold configurations on sterndrive and MIE inboard applications from 1996 through 2001. Existing intake gaskets must not be reused after the manifold or plenum has been removed — a full replacement set is required at each service.

Compatible Applications

Confirm fitment by MerCruiser engine serial number and the specific intake manifold / intake plenum diagram before ordering. Big-block 454 and 502 MerCruiser engines were built in multiple EFI, MPI, Gen V, and Gen VI configurations with different intake manifold assemblies.

Sterndrive Applications

• MerCruiser 7.4L MPI — 1996–2001
• MerCruiser 7.4LX MPI
• MerCruiser 454 EFI — Gen V — 1994–1996
• MerCruiser 454 MAG MPI
• MerCruiser 454 MAG Bravo MPI — Gen VI — 1996–1997
• MerCruiser 454 MAG Horizon
• MerCruiser 8.2L MPI — 1996–2001
• MerCruiser 502 EFI — Gen V — 1993–1995
• MerCruiser 502 MAG MPI
• MerCruiser 502 MAG Bravo MPI — Gen VI — 1996

MIE Inboard Applications

• MerCruiser MIE 7.4L MPI — Gen V — 1995–1996
• MerCruiser MIE 7.4L MPI — Gen VI — 1996–1997
• MerCruiser MIE 7.4LX Bravo MPI — Gen V — 1996
• MerCruiser MIE 8.2L MPI — Gen VI — 1996–1997

Not sure it fits? Send us your MerCruiser engine serial number before ordering.

Kit Contents

805522A1 is an 8-piece gasket set covering the intake manifold and intake plenum sealing surfaces on applicable 7.4L and 8.2L MPI engines. The set includes all intake manifold and plenum gaskets required for a complete intake service on covered applications. Individual gasket breakdown is not published in the OEM catalog listing — confirm with your Mercury parts diagram that the set covers all gaskets required for the specific intake assembly being serviced.

Part Numbers

• 805522A1 — Current Mercury / MerCruiser OEM part number
• 27-805522A1 — Full Mercury / Quicksilver catalog number

No separate superseding Mercury part number is confirmed in current OEM parts references.

When to Replace

Replace the intake manifold gasket set when:

• The intake manifold or plenum is removed for any reason
• Vacuum leakage is present or suspected around the intake assembly
• Coolant or air-fuel mixture leakage is indicated at the intake sealing surfaces
• Existing gaskets are crushed, hardened, torn, or deformed
• Intake-system service requires separation of the manifold or plenum components
• Engine top-end or rebuilding work disturbs the original intake gaskets

Do not reuse intake manifold or plenum gaskets after removal — even gaskets that appear undamaged after disassembly should be replaced with 805522A1.

Service Interval

Replace at every intake manifold or plenum removal — there is no hour-based service interval for intake gaskets. On 7.4L and 8.2L MPI engines with suspected vacuum leaks, rough idle, lean running, or intake-area coolant seepage, the intake manifold gaskets and plenum sealing surfaces should be inspected and the gasket set replaced during diagnosis and repair. A fresh 805522A1 set should always be on hand before beginning any intake service on a covered engine.

Installation Notes

• Confirm 805522A1 is the correct gasket set for the specific engine serial number and the intake manifold / plenum diagram before beginning intake service
• Remove all old gasket material from the intake manifold, plenum, and block sealing surfaces without scoring or gouging the mating faces
• Inspect the intake manifold and plenum sealing surfaces for warping, corrosion, or damage before reassembly
• Keep all intake ports and coolant passages covered and clean during service to prevent debris from entering the engine
• Confirm all 8 gaskets are accounted for and positioned correctly before torquing the manifold
• Follow the applicable MerCruiser 7.4L / 8.2L service manual for gasket placement, tightening sequence, and torque specifications — torque in stages as specified
• Reconnect and inspect all vacuum, fuel, and electrical connections disturbed during intake service before returning the engine to operation
• After completing intake service, run the engine to operating temperature and check for leaks at all intake sealing surfaces before returning to service

Technical FAQ

Q: Does 805522A1 cover both the 454 and 502 engines?
Yes. 805522A1 is verified for selected MerCruiser 7.4L / 454 CID and 8.2L / 502 CID MPI engine applications. However, not all 454 or 502 MerCruiser engines use the same intake manifold configuration. Confirm the engine serial number and the specific intake manifold diagram calls for 805522A1 before ordering — particularly on Gen V versus Gen VI engines and EFI versus MPI configurations.

Q: Does this fit both sterndrive and inboard (MIE) engines?
Yes. 805522A1 is used on both MerCruiser sterndrive and MIE inboard 7.4L and 8.2L MPI engine applications where the intake manifold diagram calls for this part number.

Q: Is 805522A1 a full engine rebuild gasket set?
No. 805522A1 is specifically an intake manifold and plenum gasket set — it covers the intake manifold and plenum sealing surfaces only. It does not include head gaskets, exhaust manifold gaskets, or other engine sealing components. Use it for intake manifold and plenum service only.

Q: Can I reuse the old intake gaskets after removing the manifold?
No. Intake manifold and plenum gaskets should not be reused after removal. A fresh 805522A1 set is required at each intake service, even if the removed gaskets appear undamaged.

Q: My 7.4L MPI has a rough idle and lean condition — could this be an intake gasket issue?
Vacuum leaks from failed intake manifold or plenum gaskets are a known cause of rough idle, lean running, and inconsistent throttle response on 7.4L and 8.2L MPI engines. A smoke test or propane enrichment check around the intake sealing surfaces will help confirm an intake gasket leak before removing the manifold for replacement.

Parts Desk Insights

The main thing to be aware of with 805522A1 is that it is an intake manifold and plenum gasket set only — not a full top-end or overhaul gasket kit. Customers rebuilding or resealing a big-block MerCruiser sometimes expect a broader kit and are surprised when head gaskets or exhaust gaskets are not included. It is also worth confirming Gen V versus Gen VI and EFI versus MPI intake configuration before processing the order, as different intake assemblies on the same engine family can use different gaskets. Serial number verification is the most reliable way to confirm the right gasket set for the exact engine.