This comprehensive service repair manual is specifically designed for the 2000-2008 MerCruiser 496 CID / 8.1L gasoline engine and covers a wide range of models, including the 496 Mag HO, 496 Mag, 8.1S HO, and 8.1S Horizon. It provides detailed information for both sterndrive (MCM) and inboard (MIE) configurations.

The manual is structured in a clear and logical manner, beginning with essential information about general operation, maintenance procedures, and troubleshooting techniques. It then delves into the intricacies of engine removal and installation, covering both MCM and MIE models. A dedicated section focuses on the 496 cid (8.1L) engine, providing in-depth coverage of its components and systems.

The manual's scope extends to encompass the electrical system, encompassing the starting, ignition, and charging systems. It also covers the fuel system, including a comprehensive guide to electronic fuel injection, disassembly, and reassembly.

The cooling and exhaust systems are discussed in detail, including information on closed-cooled models, manifolds, elbows, and collectors. A dedicated section covers drives, specifically the Velvet Drive 5000 Series Transmission and Hurth Transmission. Finally, the manual concludes with a section on power steering systems.

In addition to the main service manual, the package also includes the Gen III Cool Fuel Supplement. This supplement provides specialized information on Gen III Cool Fuel models, covering removal and disassembly, assembly and installation, troubleshooting, repair, and detailed fuel and coolant flow diagrams.

By employing the knowledge and guidance found within this manual, you can confidently navigate the complexities of maintaining and repairing your MerCruiser engine. The manual's comprehensive content, step-by-step instructions, clear illustrations, and detailed specifications make it an invaluable resource for both professional technicians and advanced DIY mechanics.

The MerCruiser 496 CID/8.1L engine, produced from 2000 to 2008, is a powerful and reliable gasoline engine designed specifically for marine applications. It boasts a displacement of 496 cubic inches (8.1 liters), generating a substantial amount of horsepower. This engine is commonly found in a wide range of recreational boats, from cruisers and sport boats to larger yachts, due to its robust construction and high performance capabilities. The MerCruiser 496 CID/8.1L engine is known for its smooth operation and exceptional torque, making it ideal for powering boats with a variety of hull designs and weights. Its powerful nature allows for effortless acceleration and cruising speeds, while its reliability ensures that boaters can enjoy countless hours on the water without encountering any major issues.

The engine features a cast-iron block and aluminum cylinder heads, offering durability and efficient heat dissipation. It incorporates a sophisticated fuel injection system for precise fuel delivery and optimal combustion, resulting in efficient fuel consumption and reduced emissions. The MerCruiser 496 CID/8.1L is further equipped with advanced features like a closed-loop cooling system, a high-performance exhaust manifold, and a robust crankshaft. These features contribute to the engine's overall performance, durability, and long lifespan. The 496 CID/8.1L is a popular choice for boat owners seeking a powerful and reliable engine for their marine adventures. With proper maintenance and care, this MerCruiser engine can provide years of exceptional performance and enjoyment on the water.