496
CID (8.1L)
SERVICE MANUAL NUMBER 30
4.
Check cylinder head gasket surfaces for warpage with a machinist’s straight-edge and
a feeler gauge, as shown. Take measurements diagonally across surfaces (both ways)
and straight down center. If surfaces are warped more than .003 in. (0.07 mm) in a 6 in.
area or .007 in. (0.17 mm) overall, block must be resurfaced by an automotive machine
shop.
a
b
72566
a - Machinist’s Straight Edge
b - Feeler Gauge
CYLINDER CONDITIONING
1.
2.
Performance of the following operation depends upon engine condition at time of repair.
If cylinder block inspection indicates that block is suitable for continued use (except for
out-of-round or tapered cylinders), they can be conditioned by honing or boring.
3.
4.
If cylinders have less than .005 in. (0.127 mm) taper or wear, they can be conditioned
with a hone and fitted with high limit standard size piston. A cylinder bore of more than
.005
in. wear or taper may not clean up entirely when fitted to a high limit piston. To
entirely clean up the bore, it will be necessary to bore for an oversize piston. If more than
in. taper or wear, bore and hone to smallest oversize that will permit complete
.005
resurfacing of all cylinders.
When pistons are being fitted and honing is not necessary, cylinder bores may be
cleaned with a hot water and detergent wash. After cleaning, swab cylinder bores
several times with light engine oil and a clean cloth, then wipe with a clean dry cloth.
CYLINDER HONING
1.
2.
Follow hone manufacturer’s recommendations for use of hone.
Several times, during the honing operation, clean cylinder bore and check piston for cor-
rect fit in cylinder.
3.
When finish-honing a cylinder bore to fit a piston, move hone up and down at a sufficient
speed to obtain very fine uniform surface finish marks in a crosshatch pattern of approxi-
mately 30 degrees to cylinder bore. Finish marks should be clean but not sharp, free
from imbedded particles and torn or folded metal.
4.
Permanently mark piston (for cylinder to which it has been fitted) and proceed to hone
cylinders and fit remaining pistons.
IMPORTANT: Handle pistons with care and do not attempt to force them through
cylinder until cylinder is honed to correct size.
Page 3A-96
INDEX
90-863161 SEPTEMBER 2000
| Categories | Mercury MerCruiser Manuals |
|---|---|
| Tags | Mercury MerCruiser 496 CID |
| Model Year | 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 |
| Download File |
|
| Document File Type | |
| Copyright | Attribution 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. How many openings for crankcaseventilation is there on
Merc 496 HO ?
Great down load . it was all there an more