Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 1 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 2 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 3 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 4 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 5 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 6 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 7 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 8 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 9 of 355
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30, 1998,1999,2000,2001,2002,2003,2004,2005,2006,2007,2008,2009,2010,2011 - 10 of 355
From inside (document excerpt):
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