Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30

FUEL SYSTEM
Section 5B - Fuel Injection Disassembly And Reassembly
Precautions  . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications  . . . . . . . . . . . . . . . .
Intake Manifold, Fuel Rail
5B-2
5B-3
Main System And Fuel Pump Relays  . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Electronic Control Module (ECM) . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature
(ECT) Sensor  . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure
5B-12
5B-12
5B-12
5B-12
5B-13
5B-13
5B-13
5B-13
And Throttle Body Exploded View . . . . .
Fuel Pressure Relief Procedure  . . . . . . .
Flame Arrestor . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body  . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control (IAC) Valve  . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
5B-3
5B-4
5B-4
5B-4
5B-4
5B-4
5B-5
5B-14
5B-14
5B-14
5B-14
5B-5
5B-7
5B-7
5B-8
5B-9
(MAP) Sensor . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
5B-15
5B-15
5B-15
5B-15
5B-9
5B-10
5B-10
5B-10
5B-10
5B-11
5B-11
5B-11
5B-11
COOLING SYSTEM
Section 6A - Closed Cooling
Torque Specifications  . . . . . . . . . . . . . . . .
6A-2
6A-2
6A-2
6A-2
6A-2
6A-2
6A-4
6A-6
6A-6
6A-7
6A-7
6A-7
6A-8
6A-8
6A-9
6A-9
6A-9
6A-10
6A-10
6A-10
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . .
6A-11
6A-11
6A-11
6A-11
6A-12
6A-13
6A-13
6A-13
6A-14
6A-14
6A-14
6A-15
6A-15
6A-16
6A-17
Lubricants / Sealants / Adhesives  . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . .
Closed Cooling System Capacity  . . .
Thermostat  . . . . . . . . . . . . . . . . . . . . . .
Pressure Cap Rating . . . . . . . . . . . . . .
Coolant And Water Flow Diagrams  . . . .
Pressure Cap Maintenance . . . . . . . . . . .
Seawater Pickup Pump Maintenance  . .
Testing Closed Cooling System  . . . . . . .
Testing Coolant for Alkalinity  . . . . . . .
Pressure Testing System  . . . . . . . . . .
Heat Exchanger . . . . . . . . . . . . . . . . . . . . .
Testing And Inspection  . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly  . . . . . . . . . . . . . . . . . . . . .
Cleaning   . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger Repair . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning And Inspection . . . . . . . . . . .
Testing  . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Crossover . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Inspection  . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Changing Coolant  . . . . . . . . . . . . . . . . . . .
Coolant Recommendations  . . . . . . . .
Draining Instructions  . . . . . . . . . . . . . .
Cleaning Closed Cooling System . . . . . .
Filling Closed Cooling System  . . . . . . . .
Auxiliary Hot Water Heater Installation  .
Page x
90-863161   SEPTEMBER 2000
Product Specification
CategoriesMercury MerCruiser Manuals
Tags
Model Year1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011
Download File
Please Enter the Security Characters Shown Below. Letters are Case Sensitive. Your download link will appear upon completing this step.
- 355 pages
Document File TypePDF
CopyrightAttribution Non-commercial
(2 votes, average: 4 out of 4)
Marine readers have rated Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30 4.0 out of 4.0 based on 2 product reviews.
Submit your review (optional)
(will not be displayed)
12345
* Required Field
Mercury MerCruiser 496 CID 8.1L Gasoline Marine Engines Service Manual Number 30 SKU UPC Model
Sven-Erik Walin on Jun 10, 2018. crankcase ventilation

How many openings for crankcaseventilation is there on
Merc 496 HO ?
John fox on Apr 11, 2018. Manual

Great down load . it was all there an more

Leave a Reply

Your email address will not be published. Required fields are marked *

*
*
Website