2001-2011 Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Owners Manual Number 30 - English

SERVICE MANUAL
Number 30
496CID/8.1L GASOLINE ENGINE

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011
Notice

Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY!

These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures.
Models Covered in This Manual

Sterndrive (MCM) Model
496 Mag HO
496 Mag

Serial Number
0M000000 & Up
0M000000 & Up

Inboard (MIE) Model
8.1S HO
8.1S Horizon

90-863161 SEPTEMBER 2000

Serial Number
0M000000 & Up
0M000000 & Up

User and Operator’s Vehicle Manual Guide. Free Auto PDF Manual Download.

Service Manual Outline

Section 1 – Important Information
A – General Information
B – Maintenance
C – Troubleshooting

Section 2 – Removal and Installation
A – MCM Models
B – MIE Models

Section 3 – Engine
A – 496 cid (8.1L)
Section 4 – Electrical System
A – Starting System
B – Ignition System
C – Charging System
Section 5 – Fuel System
A – Fuel Delivery System for Electronic Fuel Injection B – Fuel Injection Disassembly and Reassembly
Section 6 – Cooling System
A – Closed Cooled Models
Section 7 – Exhaust System
A – Manifolds and Elbows
B – Collectors
Section 8 – Drives
A – Velvet Drive 5000 Series Transmission B – Hurth Transmission
Section 9 – Power Steering
A – Pump
Important Information 1
Removal And Installation 2
Engine 3
Electrical System 4
Fuel System 5
Cooling System 6
Exhaust System 7
Drives 8
Power Steering 9

90-863161 SEPTEMBER 2000 Page v
Section 1A – General Information

Source: maxumownersclub.com