Mercury Mercruiser Sterndrives 496 CID 8.1L 2000 2001 2002 2003 2004 2005 2006 2007 2008 Factory Service Repair Manual

Price range: $39.00 through $48.00

Mercury Mercruiser Sterndrives 496 CID 8.1L 2000 2001 2002 2003 2004 2005 2006 2007 2008 Factory Service Repair Manual

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Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your MERCURY.

355 Pages

Medium

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SKU: N/A Categories: Watercrafts/Boats, Mercury

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Mercury Mercruiser Sterndrives 496 CID 8.1L 2000 2001 2002 2003 2004 2005 2006 2007 2008 Factory Service Repair Manual

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury.

355 Pages

MODEL YEAR:

2000 2001 2002 2003 2004 2005 2006 2007 2008

MODELS COVER:

Sterndrive (MCM) Model:

496 Mag HO

496 Mag

Inboard (MIE) Model:

8.1S HO

8.1S Horizon

MANUAL COVERS:

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

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English
Format: PDF

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.)

Windows/Mac/Tablet/Phone Friendly

During the period of 2000–2008, Mercury MerCruiser offered the 496 cubic inch (8.1L) big-block V8 engine in two main versions: the standard 496 MAG and the higher-performance 496 MAG HO (High Output). These engines were typically paired with a heavy-duty Bravo sterndrive, such as the Bravo One, Two, or Three.

Engine specifications

Both engines share the same fundamental architecture, based on the GM Vortec 8100 big-block, but the HO version has internal and computer programming differences to achieve more horsepower.

Feature	496 MAG (8.1L)	496 MAG HO (8.1L)
Horsepower	375 hp	425 hp
Torque	502 lb-ft (approximate)	548 lb-ft (approximate)
Fuel System	Multi-Port Injection (MPI)	Multi-Port Injection (MPI)
Electronics	Digital Throttle and Shift (DTS) on later models	Digital Throttle and Shift (DTS) on later models
Cooling	Closed-circuit cooling	Closed-circuit cooling
Key Upgrades	N/A	Higher compression pistons, modified camshaft, and different engine control module (ECM) programming

Features and technology

The 496 CID engines included several advanced features for their time:

SmartCraft: Both engines were equipped with the SmartCraft system, which provided integrated engine diagnostics and vessel information.
Engine Guardian: This feature monitored critical engine parameters like oil pressure and temperature and could automatically reduce power to prevent damage.
Closed-circuit cooling: This feature helped protect the engine from the corrosive effects of seawater by circulating coolant.
Dry-joint exhaust: Mercruiser introduced a dry-joint exhaust system in the mid-2000s, which improved corrosion resistance by reducing the potential for water leaks.

Common issues

During this era, owners of the 496 CID engine often experienced issues with the Cool Fuel 3 module, particularly with older versions.

Fuel contamination: The paint used inside the early modules could be dissolved by ethanol in the fuel, leading to flakes clogging the injectors and fuel pressure regulator.
Module leaks: The original design used press-fit cooling hoses that were prone to leaking and breaking. This was later updated to a threaded fitting design.
High-RPM cutouts: Intermittent fuel delivery issues could cause the engine to cut out or limit RPMs under high load.