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