MerCruiser 496 MAG Bravo User Manual

© 2006 Mercury Marine 496 MAG Bravo Models 90-864839061 1106
NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury
MerCruisers’ instructions complies with the requirements of the following directives
by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement Standards Applied
Owner’s manual (A.2.5) ISO 10240
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4) ISO 8665
Inboard Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO 10133
Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469
Electrical System (A.5.3) ISO 10133; ISO 8846
Steering system (A.5.4)
Applicable portions of: ISO 10592, ISO 8848 and
ABYC P‑17
Exhaust emission requirements (B.2) ISO 8178
Owner’s manual (B.4) ISO 8665
Noise emission levels (C.1) ISO 14509
Ignition‑protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031
Mercury MerCruiser declares that our sterndrive or inboard engines without integral
exhaust, when installed in a recreational craft, in accordance with the manufacturers
supplied instructions, will meet the exhaust emissions requirements of the directive
mentioned above. This engine must not be put into service until the recreational craft
in which it is to be installed has been declared in conformity, if so required, with the
relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard EN 50081‑1
Generic immunity standard EN 50082‑1
Vehicles, boats and internal combustion engine
driven devices ‑ Radio disturbance characteristics
SAE J551 (CISPR 12)
Electrostatic discharge testing EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
The notified body responsible for surveillance of the quality system under Full Quality Assurance
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

MerCruiser 496 MAG Bravo Specifications

General

Engine Type	V8
Gear Ratio	1.5:1
Displacement	8.1 L (496 cu in)
Horsepower	375 hp
Fuel System	Multi-Port Fuel Injection
Cooling System	Closed Cooling
Ignition System	Electronic
Exhaust System	Through Prop Exhaust
Alternator Output	65 Amp
Recommended Fuel	87 Octane
Bore x Stroke	4.25" x 4.37" (108 x 111 mm)

Summary

Section 1 - Warranty

Warranty Registration: United States and Canada

Details US and Canada warranty registration process.

Warranty Registration: Outside the United States and Canada

Outlines warranty registration for regions outside North America.

Transfer of Warranty

Explains how to transfer the product warranty to a new owner.

Mercury Product Protection Plan: United States and Canada

Describes optional extended warranty plan for US/Canada.

Mercury MerCruiser Limited Warranty (Gasoline-Fueled Products Only)

Covers standard limited warranty for gasoline-fueled MerCruiser engines.

3-Year Limited Warranty Against Corrosion

Details a three-year warranty for corrosion protection.

4-Year Limited Corrosion Warranty: SeaCore Sterndrive Models with Gas Engines

Provides four-year corrosion warranty for SeaCore sterndrive models.

Global Warranty Charts

Summarizes warranty coverage by region and boat brand.

Consumer Application Warranty Chart

Details warranty terms for consumer use by region/brand.

Commercial Application Warranty Chart

Outlines warranty terms for commercial use by region/brand.

Government Application Warranty Chart

Specifies warranty coverage for government use by region.

Mercury Installation Quality Certification Program

Explains builder certification program and its warranty benefits.

California Emissions Limited Warranty

Details emissions control warranty for California regulations.

Section 2 - Getting to Know Your Power Package

Identification

Explains how to identify engine/drive unit via serial numbers.

Bravo Sterndrive Serial Number and Identification

Locates serial number/identification on Bravo sterndrives.

Bravo Transom Serial Number

Identifies location of the Bravo transom serial number.

Lanyard Stop Switch

Describes purpose and function of the lanyard stop switch for safety.

Instrumentation

Overview of boat gauges for monitoring engine/boat functions.

System View

Explains SC5000 SmartCraft System View display and its features.

Digital Gauges

Details functions and information from digital gauges.

Analog Gauges

Explains common analog gauges and their readings.

Remote Controls (Non-DTS Models)

Covers features/operation of non-DTS remote controls.

Remote Controls (DTS Models)

Details features/operation of DTS remote controls.

Zero Effort Features

Explains "Zero Effort" control system features and operation.

Power Trim

Describes function and operation of the power trim system.

Electrical System Overload Protection

Explains how circuit breakers/fuses protect the electrical system.

Audio Warning System

Details audio warning system and its alert functions for engine issues.

Engine Guardian Strategy

Explains how Engine Guardian System protects engine from damage.

Warning Horn Signals

Describes different warning horn signals and their meanings.

Section 3 - On The Water

Safe Boating Suggestions

Provides general recommendations for safe boating practices/regulations.

Be Alert To Carbon Monoxide Poisoning

Warns about carbon monoxide dangers and ventilation.

Good Ventilation

Explains ensuring proper boat ventilation to remove fumes.

Poor Ventilation

Discusses poor ventilation scenarios and CO exposure risks.

Basic Boat Operation (Non-DTS Models)

Covers fundamental boat operation for non-DTS models.

Launching and Boat Operation

Guides boat launching and basic operational procedures.

Starting and Stopping the Engine

Details procedures for starting and stopping the engine.

Throttle Only Operation

Explains using throttle-only function for starting/low-speed.

Trailering the Boat

Instructions for preparing boat and sterndrive for trailering.

Freezing Temperature Operation

Precautions for operating in freezing temps to prevent damage.

Drain Plug and Bilge Pump

Importance of checking drain plugs/bilge pumps for water damage prevention.

Basic Boat Operation (DTS Models)

Covers fundamental boat operation for DTS models.

Protecting People In The Water

Safety advice regarding people in water and boat operation.

High-Speed And High-Performance Boat Operation

Guidance for operating high-speed/high-performance boats.

Passenger Safety In Pontoon Boats And Deck Boats

Safety considerations for passengers in pontoon/deck boats.

Boats Having An Open Front Deck

Safety advice for boats with open front decks.

Boats With Front-Mounted, Raised Pedestal Fishing Seats

Safety notes for front-mounted pedestal fishing seats.

Wave And Wake Jumping

Warnings and advice about jumping waves or wakes.

Impact With Underwater Hazards

Precautions for operating in shallow water/areas with underwater obstacles.

Drive Unit Impact Protection

How drive unit hydraulic system provides impact protection.

Operating With Low Water Inlets In Shallow Water

Guidance on operating with low water inlets in shallow conditions.

Conditions Affecting Operation

Factors influencing boat operation: weight, water conditions.

Weight Distribution (Passengers and Gear) Inside the Boat

How weight distribution affects boat handling and performance.

Bottom Of Boat

Importance of clean, smooth boat bottom for performance.

Cavitation

Explanation of cavitation and its common causes.

Ventilation

Explanation of ventilation and its causes, e.g., air in water.

Elevation And Climate

How elevation and climate affect engine performance.

Propeller Selection

Guidelines for choosing correct propeller for optimal engine performance.

Getting Started

Initial steps and considerations before operating the boat.

20-Hour Break-In Period

Instructions for critical 20-hour engine break-in period.

After Break-In Period

Recommendations for maintenance after the break-in period.

End of First Season Checkup

Guidance on first season's scheduled maintenance.

Section 4 - Specifications

Fuel Requirements

Info on suitable gasoline types for the engine.

Fuel Ratings

Details octane requirements for gasoline in various regions.

Using Reformulated (Oxygenated) Gasolines (USA Only)

Notes on using oxygenated gasolines in the USA.

Gasolines Containing Alcohol

Warnings on alcohol effects in gasoline on the fuel system.

Engine Oil

Recommended engine oils and specs based on temperature.

Engine Specifications (496)

Technical specifications for the 496 engine model.

Fluid Specifications (496)

Capacities/types of fluids for 496 engine and sterndrives.

Engine

Details on engine fluid capacities and types.

Bravo Sterndrives

Fluid capacities and types for Bravo sterndrive units.

Power-Assisted Steering and Power Trim Fluids

Approved fluids for power steering and power trim systems.

Approved Power-Assisted Steering Fluids

Lists approved fluids for the power steering system.

Approved Power Trim Fluids

Lists approved fluids for the power trim system.

Section 5 - Maintenance

Owner/Operator Responsibilities

Outlines owner's duties for maintaining the power package.

Dealer Responsibilities

Lists dealer responsibilities for customer service.

Maintenance

Introduction to the maintenance section and its importance.

Do It Yourself Maintenance Suggestions

Advice for owners performing own maintenance tasks.

Inspection

Guidance on regular inspection of power package for optimal performance.

Maintenance Schedule - Sterndrive Models

Comprehensive maintenance schedule for sterndrive models.

Routine Maintenance

Daily, weekly, and bi-monthly maintenance tasks.

Scheduled Maintenance

Tasks required at specific hour intervals or annually.

Maintenance Log

Instructions for keeping a record of performed maintenance.

Engine Oil

Procedures for checking, filling, and changing engine oil.

Changing Oil and Filter

Detailed steps for changing engine oil and filter.

Power Steering Fluid

How to check, fill, and change power steering fluid.

Engine Coolant

Procedures for checking and filling engine coolant.

Drive Unit Oil

Steps for checking, filling, and changing drive unit oil.

Power Trim Fluid

How to check, fill, and change power trim fluid.

Battery

Precautions and advice for handling/maintaining batteries.

Cleaning The Flame Arrestor

Steps for safely cleaning the flame arrestor.

Cleaning The IAC Muffler

Instructions for cleaning the Idle Air Control (IAC) muffler.

Water-Separating Fuel Filter (496)

Procedure for replacing water-separating fuel filter.

GEN III Models

Specific removal/installation for GEN III fuel filters.

Lubrication

General lubrication points/procedures for steering system.

Steering System

Lubrication procedures for steering cable and components.

Throttle Cable

Lubrication of throttle cable pivot points/guide surfaces.

Shift Cable - Typical

Lubrication of shift cable pivot points/guide surfaces.

Sterndrive Unit and Transom Assembly

Lubrication of gimbal bearing and related components.

Engine Coupler

Lubrication of engine coupler splines and related parts.

Driveshaft Extension Models

Lubrication of driveshaft extension fittings/U-joints.

Propellers

Info on propeller repair and removal procedures.

Propeller Repair

How to get damaged propellers repaired.

Bravo Sterndrive Propeller Removal

Step-by-step guide to removing Bravo sterndrive propellers.

Bravo One Models

Specific propeller removal steps for Bravo One models.

Bravo Two Models

Specific propeller removal steps for Bravo Two models.

Bravo Three Models

Specific propeller removal steps for Bravo Three models.

Bravo Sterndrive Propeller Installation

Step-by-step guide to installing Bravo sterndrive propellers.

Serpentine Drive Belt

Inspection/replacement procedures for serpentine drive belt.

Corrosion Protection

Info on preventing corrosion on the power package.

Maintaining Ground Circuit Continuity

Importance of ground circuit continuity for MerCathode System.

Anodes and MerCathode System Locations

Identifies locations of sacrificial anodes and MerCathode system.

Checking the Quicksilver MerCathode System

How to test MerCathode system for adequate output.

Power Package Exterior Surfaces

Care and maintenance of power package exterior finish.

Boat Bottom Care

Importance of keeping boat bottom clean for performance.

Anti-fouling Paint

Guidelines and precautions for applying anti-fouling paint.

Sterndrive Surface Care

Recommendations for maintaining sterndrive surface and finish.

Flushing the Power Package

Procedures for flushing power package cooling system.

Sterndrive Water Pickups

Types of sterndrive water pickups and their flushing requirements.

Alternative Water Pickups

Flushing procedures for alternative water pickup systems.

The SeaCore Power Package Flushing Procedure

Specific flushing procedure for SeaCore power packages.

Section 6 - Storage

Cold Weather or Extended Storage

Recommendations for preparing boat for cold weather/extended storage.

Preparing Power Package for Storage

Detailed steps for preparing engine/fuel system for storage.

Engine and Fuel System Preparation

Steps for preparing engine/fuel system prior to storage.

Draining the Seawater System

Procedures for draining engine's seawater cooling system.

Drain System Identification

Identifies type of drain system installed on power package.

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

Instructions for draining system using air pressure.

MANUAL DRAIN SYSTEM

Instructions for draining system using manual drain plugs.

Air Actuated Single Point Drain System

Procedure for draining system using an air pump.

BOAT IN THE WATER

Draining procedures when boat remains in the water.

BOAT OUT OF THE WATER

Draining procedures when boat is removed from water.

Draining the Sterndrive

Specific instructions for draining the sterndrive unit.

Battery Storage

Guidelines for storing boat battery for extended periods.

Power Package Recommissioning

Steps to recommission power package after storage.

Section 7 - Troubleshooting

Diagnosing EFI Problems

Diagnosing issues with Electronic Fuel Injection (EFI) systems.

Diagnosing DTS Problems

Diagnosing issues with Digital Throttle and Shift (DTS) systems.

Engine Guardian System

Explains Engine Guardian System and its alerts.

Starter Motor Will Not Crank Engine, Or Cranks Slow

Potential causes/remedies for starter motor issues.

Engine Will Not Start Or Is Hard To Start

Troubleshooting for engines that won't start or are hard to start.

Engine Runs Rough, Misses And/Or Backfires

Diagnosing/fixing engine running issues like rough idle/backfiring.

Poor Performance

Troubleshooting common causes of reduced engine/boat performance.

Excessive Engine Temperature

Identifying and resolving engine overheating issues.

Insufficient Engine Temperature

Troubleshooting why engine may not reach optimal temperature.

Low Engine Oil Pressure

Diagnosing/fixing low engine oil pressure warnings.

Battery Will Not Come Up On Charge

Troubleshooting battery charging problems.

Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes Unusual Sounds

Resolving remote control issues like stiffness or play.

Steering Wheel Turns Hard Or Jerky

Diagnosing/fixing steering system stiffness or jerky movement.

Power Trim Does Not Operate (Motor Does Not Operate)

Troubleshooting when power trim motor does not operate.

Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)

Diagnosing power trim issues: motor runs but unit doesn't move.

Section 8 - Customer Assistance Information

Owner Service Assistance

General advice on seeking service for Mercury MerCruiser.

Local Repair Service

How to find and utilize local authorized dealers for repairs.

Service Away From Home

Guidance on obtaining service when traveling away from dealer.

Stolen Power Package

Steps to take if the power package is stolen.

Attention Required After Submersion

Critical procedures if the power package is submerged.

Replacement Service Parts

Info on using genuine Quicksilver parts and accessories.

Parts And Accessories Inquiries

How to inquire about and order replacement parts/accessories.

Resolving A Problem

Steps to resolve issues or concerns with the product.

Mercury Marine Service Offices

Contact info for Mercury Marine service offices worldwide.

Ordering Literature

How to order additional technical literature for the power package.

United States and Canada

Contact details for ordering literature in US and Canada.

Outside The United States and Canada

Contact details for ordering literature outside North America.