MerCruiser 496 MAG Owner's Manual

With emissions control

Hide thumbs Also See for 496 MAG:

User manual (146 pages)

Owner's manual (124 pages)

Table Of Contents

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

Table of Contents

Quick Links

Troubleshooting

Summary of Contents for MerCruiser 496 MAG

Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
Page 2 Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.
Page 3: Read This Manual Thoroughly
We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
Page 4 NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard.
Page 5: Table Of Contents
Mercury Product Protection Plan: United States and What Is Not Covered........12 Canada..............3 Components Of The Emission Control System 12 Mercury MerCruiser Limited Warranty Disclaimers And Limitations......14 (Gasoline‑Fueled Products Only) ......4 Mercury Installation Quality Certification Program 14 3‑Year Limited Warranty Against Corrosion....6 California Emission Control Warranty Statement.
Page 6 Starting the Engine After It Has Been Stopped Boats Having An Open Front Deck....53 While In Gear..........48 Boats With Front‑Mounted, Raised Pedestal Throttle‑Only Operation.........48 Fishing Seats...........53 Trailering the Boat.........48 Wave and Wake Jumping........54 Freezing Temperature Operation....49 Impact With Underwater Hazards......54 Drain Plug and Bilge Pump......49 Drive Unit Impact Protection......55 Basic Boat Operation (DTS Models)....
Page 7 Battery..............80 Belt Routing..........100 Multiple EFI Engine Battery Precautions..81 Checking............100 Cleaning the Flame Arrestor........81 Replacing.............101 Cleaning the IAC Muffler (Non‑DTS Models Corrosion Protection..........101 Only)..............82 Corrosion Information........101 Water‑Separating Fuel Filter.........83 Maintaining Ground Circuit Continuity..102 GEN III Models..........84 Anodes and MerCathode System Locations 102 Removal............84 Checking the Quicksilver MerCathode Installation............85...
Page 8 Power Trim Does Not Operate (Motor Does Not Power Trim Does Not Operate (Motor Operates Operate)............133 but Sterndrive Unit Does Not Move)...133 Section 8 - Customer Assistance Information Owner Service Assistance.........136 Parts and Accessories Inquiries....137 Local Repair Service........136 Resolving a Problem........137 Service Away From Home......136 Mercury Marine Service Offices.....137 Stolen Power Package........136...
Page 9: Section 1 - Warranty
Mercury Product Protection Plan: United States and System ............12 Canada..............3 Disclaimers And Limitations ......14 Mercury MerCruiser Limited Warranty (Gasoline- Mercury Installation Quality Certification Program Fueled Products Only) ......... 4 ................14 3-Year Limited Warranty Against Corrosion..6...
Page 10: Warranty Registration: United States And Canada
A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.
Page 11: Transfer Of Warranty
Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.
Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
Page 13 Section 1 - Warranty Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by Mercury Marine is completed and documented.
Page 14: 3-Year Limited Warranty Against Corrosion
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
Page 15: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines
This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
Page 16: Global Warranty Charts
Section 1 - Warranty This limited warranty does not cover the following: • Electrical system corrosion • Corrosion resulting from damage • Corrosion that causes purely cosmetic damage • Abuse or improper service • Corrosion to accessories, instruments, and steering systems •...
Page 17: Commercial Application Warranty Chart
Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...
Page 18: Government Application Warranty Chart
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year.
Page 19: What Is Covered
Section 1 - Warranty What Is Covered NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 20: How To Obtain Warranty Coverage
Section 1 - Warranty How To Obtain Warranty Coverage The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
Page 21 Section 1 - Warranty Cold start enrichment system Intake valve(s) 2. Air Induction System Controlled hot air intake system Intake manifold Air filter Turbocharger systems Heat riser valve and assembly 3. Ignition System Spark plugs Magneto or electronic ignition system Spark advance/retard system Ignition coil and/or control module Ignition wires...
Page 22: Components Of The Emission Control System 12 Disclaimers And Limitations
Owner Service Assistance for contact information. Mercury Installation Quality Certification Program 15502 Mercury MerCruiser products installed by a Mercury Installation Quality Certified Manufacturer are Installation Quality certified products and may receive an additional one (1) year of limited warranty coverage.
Page 23: Your Warranty Rights And Obligations
1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 24: Emission Control Information Label
A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.
Page 25: Owner Responsibility
Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards.
Page 26 Section 1 - Warranty The Star label will be affixed on the left side of the hull as shown. XX 1234 XX 32770 Recommended location Secondary location One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.
Page 27: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Slim Binnacle Console Mount Features - Single Engine Serial Number Decal......20 Engine............30 Bravo Sterndrive Serial Number and Console Mount Features- Dual Engine..31 Identification..........20 Synchronizing Dual Engines......32...
Page 28: Identification
Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal The serial number decal is located on top of the engine.
Page 29: Bravo Transom Serial Number
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers. 25907 Bravo sterndrive serial number stamping...
Page 30: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. 25905 Gimbal housing with serial number stamping Transom assembly serial Number...
Page 31: Instrumentation
Section 2 - Getting to Know Your Power Package The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.
Page 32: Analog Gauges
Section 2 - Getting to Know Your Power Package SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed between 500 and 1200 RPM. 26238 SmartCraft gauges Tachometer LCD system view display Speedometer The SmartCraft instrument package also aids in Engine Guardian diagnostics.
Page 33: Remote Controls (Non-Dts Models)
Section 2 - Getting to Know Your Power Package Reference Gauge Function Fuel gauge Indicates quantity of fuel in tank. Hour meter Records engine operating time. Bilge blower switch Operates the bilge blower. Ignition switch Allows the operator to start and stop engine. Power trim gauge Indicates sterndrive angle (trim up [out] and down [in]).
Page 34: Console Mount Features
Section 2 - Getting to Know Your Power Package Control Handle Tension Adjustment Screw - (not visible) This screw is used to adjust the effort required to move the remote control handle. Refer to instructions provided with remote control for complete adjustment instructions. Trim/Tilt Button - Refer to Power Trim.
Page 35: Zero Effort Features
Section 2 - Getting to Know Your Power Package Zero Effort Features 5656 Shift ever Trim/tilt switch Throttle lever Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position.
Page 36: Panel Mount Features
Section 2 - Getting to Know Your Power Package Panel Mount Features 3409 Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.
Page 37: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine 3410 Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 38: Slim Binnacle Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Slim Binnacle Console Mount Features ‑ Single Engine START STOP 14637 Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 39: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 3411 Trim/tilt switch Arrow trackpad Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw...
Page 40: Synchronizing Dual Engines
Section 2 - Getting to Know Your Power Package Synchronizing Dual Engines The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine. Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM for two seconds and remote control handles are positioned within 5°...
Page 41: Synchronizing Dual Helms Prior To Station
Section 2 - Getting to Know Your Power Package 3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STAT ION SELECT STATION SELECT 3433...
Page 42: Power Trim
Section 2 - Getting to Know Your Power Package Power Trim Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
Page 43: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
Page 44: Trim Delta
Section 2 - Getting to Know Your Power Package Trim Delta Trim delta controls the distance between the individual adjacent drive angles when trimming. The trim delta limit is preset, and will not allow extreme drive angle differences that could damage tie bars. If the maximum trim delta limit is met, the drive furthest in the trim process "up or down", will stop trimming until the adjacent drive is back within the delta limit.
Page 45 Section 2 - Getting to Know Your Power Package A 90 amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs. mc74907-1 Four fuses, located on the port side of the engine, protect various electronic fuel injection (EFI) circuits.
Page 46 Section 2 - Getting to Know Your Power Package A 15 amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine. 32206 Fuse cover 15 amp fuse Accessory harness A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system.
Page 47 Section 2 - Getting to Know Your Power Package The power trim system is protected from overload by both a 110 amp fuse and a 20 amp spade fuse on the power trim pump. The trim pump may also have an in‑line circuit protection device in the power trim positive lead near the battery switch or battery connection.
Page 48: Audio Warning System
Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
Page 49: Warning Horn Signals
If the debris passes through, and full water flow is restored, Guardian restores engine power to normal. To avoid recurrence of the problem, contact an authorized Mercury MerCruiser dealer. Warning Horn Signals Most faults will cause the warning horn circuit to activate. How the warning horn activates depends on how serious the problem is.
Page 50 Section 2 - Getting to Know Your Power Package Notes: Page 42 90-899883240 NOVEMBER 2007...
Page 51: Section 3 - On The Water
Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........44 While You Are Cruising ........ 52 Be Alert to Carbon Monoxide Poisoning..... 45 While Boat Is Stationary ....... 52 Good Ventilation ........... 45 High-Speed and High-Performance Operation Poor Ventilation ...........
Page 52: Safe Boating Suggestions
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.
Page 53: Be Alert To Carbon Monoxide Poisoning
Section 3 - On the Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;...
Page 54: Poor Ventilation
Section 3 - On the Water 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Page 55: Operation Chart
Section 3 - On the Water OPERATION CHART Operation Chart Before Starting After Starting While Underway After Stopping Observe all Observe all gauges to gauges to check check condition of condition of Turn the ignition key to the Install the bilge drain plug. engine.
Page 56: Stopping The Engine
If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer. Page 48 90-899883240 NOVEMBER 2007...
Page 57: Freezing Temperature Operation
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 58: Starting And Stopping The Engine
Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.
Page 59: Stopping The Engine
Section 3 - On the Water NOTICE Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is operating at idle. STOPPING THE ENGINE 1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed.
Page 60: Trailering The Boat
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 61: High-Speed And High-Performance Operation
Section 3 - On the Water High‑Speed and High‑Performance Operation If your boat is considered a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat.
Page 62: Wave And Wake Jumping
Section 3 - On the Water Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. mc79680-1 Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water.
Page 63: Drive Unit Impact Protection
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 64: Conditions Affecting Operation
Section 3 - On the Water Extreme care should be exercised when operating a boat equipped with low water inlets while maneuvering in shallow water. Also, avoid beaching a boat with the engine operating. Conditions Affecting Operation Weight Distribution (Passengers and Gear) Inside the Boat Shifting weight to rear (stern): •...
Page 65: Propeller Selection
Section 3 - On the Water • Higher temperatures • Low barometric pressures • High humidity For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating weather conditions.
Page 66: After Break-In Period
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
Page 67: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........60 Engine............62 Fuel Ratings ..........60 Bravo Sterndrives..........62 Using Reformulated (Oxygenated) Gasoline Power-Assisted Steering and Power Trim Fluids (USA Only) ........... 60 ..............63 Gasoline Containing Alcohol ......60 Approved Power-Assisted Steering Engine Oil............
Page 68: Fuel Requirements
Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.
Page 69: Engine Oil
Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation, for short periods of time: 1.
Page 70: Fluid Specifications
Section 4 - Specifications 496 MAG 496 MAG H.O. Models SeaCore 496 SeaCore 496 MAG H.O. Power 280 kW (375 hp) 317 kW (425 hp) Number of cylinders Displacement 8.1 L (496 cid) Bore and stroke 108 × 111 mm (4.25 × 4.38 in.) Compression ratio 9.1:1...
Page 71: Power-Assisted Steering And Power Trim Fluids
Section 4 - Specifications Power‑Assisted Steering and Power Trim Fluids APPROVED POWER-ASSISTED STEERING FLUIDS Description Part Number Power Trim and Steering Fluid 92‑858074K01 Dexron III Automatic Transmission Fluid Obtain locally APPROVED POWER TRIM FLUIDS Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally...
Page 72 Section 4 - Specifications Notes: Page 64 90-899883240 NOVEMBER 2007...
Page 73 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......66 Sterndrive U-joint Shaft Splines And O-rings Dealer Responsibilities........66 (Sterndrive Unit Removed)......89 Maintenance............66 Engine Coupler..........89 Do It Yourself Maintenance Suggestions... 67 Driveshaft Extension Models......90 Inspection............67 Propellers............
Page 74: Owner/Operator Responsibilities
• Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...
Page 75: Do It Yourself Maintenance Suggestions
Transmission (inboard models only) Do It Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.
Page 76: Maintenance Schedule-Sterndrive Models
Section 5 - Maintenance Maintenance Schedule—Sterndrive Models Routine Maintenance NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Check the engine oil level. (You can extend this interval based on experience with the product.) •...
Page 77: Maintenance Log
• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. • Inspect the condition and the tension of the belts.
Page 78: Engine Oil
Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil Checking NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat.
Page 79: Filling
2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. All Models Capacity Fluid Type Engine oil (with filter) 8.5 L (9 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 3. Check the oil level and replace the fill cap. 90-899883240 NOVEMBER 2007 Page 71...
Page 80: Changing Oil And Filter
Section 5 - Maintenance Changing Oil and Filter See Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
Page 81: Changing The Oil Filter
Section 5 - Maintenance 3. Install the oil pump onto the dipstick tube. mc70571-1 Oil pump Dipstick tube Oil drain hose 4. Insert the hose end of the crankcase oil pump onto an appropriate container and usie the handle to pump until the crankcase is empty. 5.
Page 82: Power-Assisted Steering Fluid
Checking 1. Stop the engine and center the sterndrive unit. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. 2. Remove the fill cap from the power steering pump reservoir and observe the level. The oil level must be at the lower mark when the engine is cold and at the upper mark when the engine is warm.
Page 83: Changing
Section 5 - Maintenance 3. Install the fill cap and dipstick. Changing Power‑assisted steering fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Engine Coolant Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns.
Page 84: Changing
3. Check the antifreeze concentration for adequate freeze protection and correct if necessary. Refer to the Specifications section. 4. Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Sterndrive Gear Lube Checking NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.
Page 85: Filling
Filling IMPORTANT: If the monitor requires more than 59 ml (2 fl. oz.) of lubricant, a seal may be leaking, which can damage the sterndrive. Contact your authorized Mercury MerCruiser dealer. NOTE: If filling the entire sterndrive, see Changing .
Page 86 Section 5 - Maintenance Drain the fluid into a suitable container. mc79506-1 Oil fill and drain screw Sealing washer 5. All Other Models: Place the sterndrive unit in full trim out position. Remove the oil fill and drain screw and sealing washer. Drain the fluid into a suitable container.
Page 87: Power Trim Fluid
Section 5 - Maintenance IMPORTANT: If any water drains from the unit, or if the fluid appears milky, the sterndrive unit is leaking. See your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so the propeller shaft is level.
Page 88: Filling
3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
Page 89: Multiple Efi Engine Battery Precautions
Section 5 - Maintenance Multiple EFI Engine Battery Precautions Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for 2 different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine's alternator will not be required to supply any charging current.
Page 90: Cleaning The Iac Muffler (Non-Dts Models Only)
Section 5 - Maintenance 1. Remove the engine cover. 31609 Engine cover Flame arrestor 2. Loosen the flame arrestor clamp and remove the flame arrestor. 3. Clean the flame arrestor with solvent and dry with compressed air or set aside and allow to air dry completely.
Page 91: Water-Separating Fuel Filter
Section 5 - Maintenance 2. Remove the IAC muffler from the slot in the air valve plate using needle‑nosed pliers. 31654 Air valve plate IAC muffler location 3. Inspect the muffler for holes, cracks, or deterioration. Replace if damaged. IMPORTANT: Do not use a cleaner that contains methyl ethyl ketone and do not use cleaner on electrical connections.
Page 92: Gen Iii Models
O‑ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness.
Page 93: Installation
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Steering System...
Page 94 Section 5 - Maintenance 1. If Steering Cable Has Grease Fittings: Turn steering wheel until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand‑operated grease gun. 6221 Steering cable grease fitting Tube Ref No.
Page 95: Throttle Cable
3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 96: Shift Cable - Typical
Pivot points Guide contact surfaces Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Shift cable pivot points & guide 92‑883725K01 Oil SAE25W‑40 contact surfaces Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
Page 97: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Unit Removed)
Section 5 - Maintenance Sterndrive U‑joint Shaft Splines And O‑rings (Sterndrive Unit Removed) 1. Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. 8591 Driveshaft splines U‑joint O‑rings (3) Tube Ref No. Description Where Used Part No. Driveshaft splines and U-joint Engine Coupler Spline Grease 92-802869A1 O-rings...
Page 98: Driveshaft Extension Models
92-802870A1 Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Bravo Sterndrive Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
Page 99 Section 5 - Maintenance 1. If Equipped, straighten the bent tabs of the tab washer on the propeller shaft. 4750 Prop Tab bent down Tab washer Propeller nut Drive sleeve adapter 2. Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate.
Page 100 Section 5 - Maintenance 4. Slide the propeller and the attaching hardware from the propeller shaft. 5301 Bravo One models Propeller shaft splines Drive sleeve adapter Forward thrust hub Tab washer Flo‑Torque II drive hub Propeller nut Propeller 19816 Bravo One XR models Propeller shaft Washer Propeller hub insert with snubbers...
Page 101: Bravo Two Models
Section 5 - Maintenance BRAVO TWO MODELS 1. Straighten the bent tabs of the tab washer on the propeller shaft. 4750 Prop Tab bent down Tab washer Propeller nut Drive sleeve adapter 2. Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate.
Page 102: Bravo Three Models
Section 5 - Maintenance 4. Slide the propeller and attaching hardware from the propeller shaft. 8566 Bravo Two Propeller shaft splines Spline washer Forward thrust hub Tab washer Propeller Propeller nut BRAVO THREE MODELS 1. Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate.
Page 103: Bravo Sterndrive Propeller Installation
Section 5 - Maintenance 7. Slide the propeller and the thrust hub off the propeller shaft. 5304 Bravo Three Aft propeller nut Front propeller thrust hub Aft propeller Propeller shaft anode screw Aft propeller thrust hub Flat washer Front propeller nut Star washer Front propeller Propeller shaft anode...
Page 104 Section 5 - Maintenance Tube Ref No. Description Where Used Part No. 2-4-C Marine Lubricant with Propeller shaft splines 92-802859A1 Teflon Anti-Corrosion Grease Propeller shaft splines 92-802867Q 1 NOTE: Anti‑corrosion grease is for salt water applications only. 2. Install the propeller with the attaching hardware as shown. 3.
Page 105: Bravo Two Models
Section 5 - Maintenance 5. Bend the three tabs down into the grooves. 4750 Prop Tab bent down Tab washer Propeller nut Drive sleeve adapter BRAVO TWO MODELS IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the propeller shaft.
Page 106: Bravo Three
Section 5 - Maintenance Description lb. in. lb. ft. Bravo Two propeller nut – 4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer. 5. Bend the three tabs down into the grooves. 4750 Prop Tab bent down...
Page 107 Section 5 - Maintenance 7. Install propeller nut and torque. Description lb. in. lb. ft. Bravo Three rear propeller nut – 8. Install propeller shaft anode and screw and torque. 5304 Bravo Three Rear propeller nut Front propeller thrust hub Rear propeller Propeller shaft anode screw Rear propeller thrust hub...
Page 108: Serpentine Drive Belt
Section 5 - Maintenance Serpentine Drive Belt Belt Routing WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before inspecting the belts. 8118 Idler pulley Seawater pump pulley Water circulating pump pulley Power steering pump pulley Crankshaft pulley...
Page 109: Replacing
Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist.
Page 110: Maintaining Ground Circuit Continuity
Section 5 - Maintenance Maintaining Ground Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the engine, transom assembly, and sterndrive components. Good continuity is essential for the MerCathode System to function effectively.
Page 111: System
The MerCathode system should be tested to ensure adequate output. Perform the test where boat is moored, using the reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer for service and information . 90-899883240 NOVEMBER 2007 Page 103...
Page 112: Power Package Exterior Surfaces
Section 5 - Maintenance Reference Electrode 91‑76675T 1 Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188 Power Package Exterior Surfaces 1. Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
Page 113 • Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) UNPAINTED area on transom of the boat around these items.
Page 114: Sterndrive Surface Care
Section 5 - Maintenance Do not power‑wash a sterndrive that has a MerCathode assembly. Doing so can damage the coating on the reference wire of the MerCathode assembly and increase corrosion. 21563 Reference electrode Anode plate Sterndrive Surface Care 21083 Standard Bravo sterndrive Sacrificial trim cylinder anode Stainless steel hoses...
Page 115: Flushing The Seawater System-Sterndrive Models
Section 5 - Maintenance Description Where used Part number Mercury Phantom Black Bare metal 92‑ 802878‑1 • Spray all electrical connections with sealant. Tube Ref No. Description Where Used Part No. Liquid Neoprene All electrical connections 92- 25711 3 • Inspect the sacrificial trim tab or anode plate if equipped, at regular intervals and replace it before it is half gone.
Page 116: Sterndrive Water Pickups
Section 5 - Maintenance STERNDRIVE WATER PICKUPS There are three types of water pickups available on Mercury MerCruiser sterndrives: low water, dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), low water pickups require the flushing attachment (849996T 1), and side pickups require the flushing attachment (44357Q 2).
Page 117: The Boat In The Water-Bravo Sterndrive
12. Slowly return the throttle to idle speed position. 13. Stop the engine. 14. Immediately shut off the supply water and remove the flushing attachment. 15. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual. The Boat in the Water—Bravo Sterndrive IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of the water.
Page 118: The Boat Out Of The Water-Alternative Water Pickups
Place a block of wood between the propeller blade and the anti‑ventilation plate. 2. Remove the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual.
Page 119: The Boat In The Water-Alternative Water Pickups
15. Immediately shut off the supply water and remove the flushing attachment. 16. Install the water inlet hose to the seawater inlet of the seawater pump. Tighten the hose clamp securely. 17. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual. The Boat in the Water—Alternative Water Pickups IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of the water.
Page 120: Seacore Power Package Flushing Procedure
Section 5 - Maintenance NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine. Do not supply flush water for more than 15 seconds without the engine operating. 5. With the sterndrive in the normal operating position, completely open the water source to provide maximum water supply.
Page 121 Section 5 - Maintenance 1. Remove the boat from the water. 2. Close the seacock, if equipped. 18510 For visual clarity, the secock shown is not installed Hose fitting to engine Handle (closed position) Seacock To water source pickup attachment 3.
Page 122 Section 5 - Maintenance 7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine. 18489 Water hose Flush socket Quick‑connect fitting (water hose end) 8. Open the water source of the water hose to a full flow. 9.
Page 123 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. 25900 Quick‑connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 124 Section 5 - Maintenance 20. Insert the dust cover in the flush socket on the engine. 18490 Dust cover installed in the flush socket Dust cover Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage.
Page 125 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....118 Boat in the Water ......... 121 Preparing Power Package for Storage..118 Boat out of the Water ......123 Engine and Fuel System Preparation . . 119 Manual Drain System........125 Draining the Seawater System......
Page 126: Cold Weather Or Extended Storage
Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.
Page 127: Engine And Fuel System Preparation
Section 6 - Storage 10. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.
Page 128: Draining The Seawater System
Section 6 - Storage Draining the Seawater System CAUTION Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining.
Page 129: Manual Drain System
Section 6 - Storage MANUAL DRAIN SYSTEM 17255 Blue drain plug locations Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1.
Page 130: Section 6 - Storage
11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 131: Boat Out Of The Water
Section 6 - Storage 13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 14. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 132 11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 133: Manual Drain System
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 134: Boat Out Of The Water
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 135: Battery Storage
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage.
Page 136 Section 6 - Storage 2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect cables. Tighten each cable clamp securely when connecting. 3. Coat the terminal connections with a battery terminal anti‑corrosion agent. 4. Perform all the checks in the before starting column of the Operation Chart. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
Page 137: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 130 Low Engine Oil Pressure......132 Diagnosing DTS Problems....... 130 Battery Will Not Recharge......132 Engine Guardian System........130 Remote Control Is Difficult to Move, Has Troubleshooting Charts........130 Excessive Play, or Makes Unusual Sounds Starter Motor Will Not Crank Engine, or Cranks ..............132...
Page 138: Diagnosing Efi Problems
Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.
Page 139: Engine Will Not Start Or Is Hard To Start
Boat bottom fouled or damaged. Clean or repair as necessary. Ignition problem. See Engine Runs Rough, Misses or Backfires. Engine overheating. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed.
Page 140: Insufficient Engine Temperature
Check all throttle linkages. If any are loose or missing, Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Page 132 90-899883240 NOVEMBER 2007...
Page 141: Steering Wheel Jerks Or Is Difficult To Turn
Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or missing, Loose or missing steering fasteners or parts. see authorized Mercury MerCruiser dealer immediately. Contaminated power steering fluid. See authorized Mercury MerCruiser dealer. Power Trim Does Not Operate (Motor Does Not Operate)
Page 142 Section 7 - Troubleshooting Notes: Page 134 90-899883240 NOVEMBER 2007...
Page 143: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 136 Parts and Accessories Inquiries ... 137 Local Repair Service ........136 Resolving a Problem ........137 Service Away From Home ......136 Mercury Marine Service Offices ....
Page 144: Owner Service Assistance
Owner Service Assistance Local Repair Service If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.
Page 145: Parts And Accessories Inquiries
Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership.
Page 146: Ordering Literature
• Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...

This manual is also suitable for:

Seacore 496 Seacore 496 mag Seacore 496 mag h.o.496 mag h.o.

MerCruiser 496 MAG Owner's Manual

Section 1 - Warranty

Section 3 - on the Water

Section 4 - Specifications

Section 5 - Maintenance

Section 7 - Troubleshooting

Quick Links

Troubleshooting

Related Manuals for MerCruiser 496 MAG

Summary of Contents for MerCruiser 496 MAG

This manual is also suitable for:

Table of Contents