The Mercury MerCruiser #40 Gen III Cool Fuel Service Repair Manual (Supplement to #30 & 31) is a comprehensive guide designed to assist technicians in maintaining and repairing a range of MerCruiser models. This manual provides detailed instructions, diagrams, and manufacturer specifications to ensure proper servicing of your equipment. The manual covers a wide array of MerCruiser models, including the 5.0L MPI (Bravo) with serial numbers starting from 0W060000, the 350 MAG MPI (Bravo) with serial numbers starting from 0W060000, the 6.2L MPI (Bravo) with serial numbers starting from 0W060000, the Sterndrive 496 MAG with serial numbers starting from 0W060000, the Inboard 350 MAG MPI with serial numbers starting from 0M398372, the Inboard 6.2L MPI with serial numbers starting from 0M398395, and the Inboard 8.1L (496cid) with serial numbers starting from 0W090000. The manual provides a detailed breakdown of various systems and components, making it a valuable resource for both experienced technicians and DIY enthusiasts. **Key content areas of the manual include:** * **Important Information:** This section covers general information and essential maintenance procedures for the covered MerCruiser models. * **Gen III Cool Fuel Module:** This section focuses specifically on the Gen III Cool Fuel Module, covering removal, disassembly, assembly, and installation procedures. * **Fuel System:** This section delves into troubleshooting and repairing fuel system issues, along with a detailed fuel flow diagram. * **Cooling System:** This section covers coolant and water flow diagrams, providing a visual understanding of the cooling system's operation. The manual is designed as a service guide, providing specific information and step-by-step instructions for disassembling, assembling, inspecting, and adjusting components. Photos and illustrations complement the text, aiding in visual comprehension and ensuring accurate execution of repair procedures.

The Mercury MerCruiser #40 Gen III Cool Fuel engine is a powerful and reliable marine inboard/sterndrive engine designed to deliver exceptional performance for a variety of watercraft. This engine utilizes a revolutionary "Cool Fuel" technology, which incorporates a closed-loop cooling system that circulates fresh water around the engine's critical components, effectively reducing operating temperatures and extending engine life. The #40 Gen III Cool Fuel boasts impressive power output, offering ample torque and horsepower to propel boats with speed and efficiency. It is known for its smooth operation, minimal vibration, and quiet performance, making it a popular choice for recreational and commercial applications. This specific manual, the Mercury MerCruiser #40 Gen III Cool Fuel Service Repair Manual (Supplement to #30 & 31), caters to the specific needs of technicians and boat owners seeking comprehensive technical information related to the Cool Fuel system. It acts as a supplement to the existing service manuals for the #30 and #31 MerCruiser engines, providing detailed instructions and diagrams for servicing, troubleshooting, and repairing the unique Cool Fuel system. This manual covers a wide range of topics including the Cool Fuel system's components, operation, maintenance procedures, troubleshooting steps for common issues, and detailed repair techniques for various system components. It is an invaluable resource for ensuring the proper functioning and longevity of the Mercury MerCruiser #40 Gen III Cool Fuel engine, enabling owners and technicians to maintain their boat's performance and reliability.