This manual covers the 496 CID / 8.1L engines from the 30 Series. These V8 engines, featuring Electronic Fuel Injection (EFI) and Distributed Electronic Ignition, are designed for robust performance in marine applications. Available in Sterndrive (MCM) and Inboard (MIE) configurations, with transmission options including Velvet Drive 5000 Series and Hurth Transmission, these powerplants are engineered for reliability and efficiency. Specific models covered include the 496 Mag HO and 496 Mag for MCM, and the 8.1S HO and 8.1S Horizon for MIE applications, all from serial number 0M000000 and up.
The purpose of this comprehensive English service manual is to provide detailed guidance for the maintenance, repair, and troubleshooting of your engine. It offers in-depth information on all critical systems, including the engine itself, electrical system, fuel system, cooling system, exhaust system, and power steering. With sections dedicated to general information, removal and installation procedures, and scheduled maintenance, this manual equips owners, technicians, and mechanics with the necessary knowledge to ensure optimal performance and longevity of their marine propulsion system.
MERCURY MERCRUISER 496CID/8.1L #30 SERVICE MANUAL
(pdf version)
Models Covered in This Manual
Sterndrive (MCM) Model Serial Number
496 Mag HO 0M000000 & Up
496 Mag 0M000000 & Up
Inboard (MIE) Model Serial Number
8.1S HO 0M000000 & Up
8.1S Horizon 0M000000 & Up
This is a very comprehensive workshop manual for your MERCRUISER marine engines. This manual has been written in a format that is designed to meet the needs of Mercury Marine technicians worldwide. You will never be dissapointed with the contents of this engine workshop manual.
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
MERCURY MERCRUISER 496CID/8.1L #30 SERVICE MANUAL
(pdf version)
Models Covered in This Manual
Sterndrive (MCM) Model Serial Number
496 Mag HO 0M000000 & Up
496 Mag 0M000000 & Up
Inboard (MIE) Model Serial Number
8.1S HO 0M000000 & Up
8.1S Horizon 0M000000 & Up
This is a very comprehensive workshop manual for your MERCRUISER marine engines. This manual has been written in a format that is designed to meet the needs of Mercury Marine technicians worldwide. You will never be dissapointed with the contents of this engine workshop manual.
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
