MerCruiser 496 MAG User Manual

© 2007 Mercury Marine 496 MAG & SeaCore 496 Models with Emissions Control
*899883240*
90-899883240 1107
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 Specifications

General

Engine Type	V8
Displacement	8.1L (496 CID)
Horsepower	375 HP
Maximum RPM	5000 RPM
Compression Ratio	9.1:1
Alternator	65 Amp
Bore x Stroke	4.25 in x 4.37 in
Fuel Type	87 Octane
Cooling System	Closed Cooling

Summary

Declaration of Conformance

Recreational Craft Directive Compliance

Details compliance with Recreational Craft Directives.

Electromagnetic Compatibility Directive Compliance

Details compliance with EMC Directives.

Identification Record

Engine Identification Details

Record for engine model, horsepower, and serial number.

Sterndrive Identification Details

Record for sterndrive serial number and unit serial number.

Transmission Identification Details

Record for inboard transmission model and serial number.

Propeller Specification Record

Record for propeller number, pitch, and diameter.

Hull and Purchase Information

Record for Hull Identification Number and purchase date.

Boat Manufacturer and Model Information

Record for boat manufacturer, model, and length.

Emissions Certification Number Record

Record for exhaust gas emissions certification number.

Warranty Information and Safety Alerts

Importance of Reading the Manual

Emphasizes the critical need to thoroughly read the manual.

Understanding Safety Alert Symbols

Explains DANGER, WARNING, and CAUTION safety symbols.

Important Safety Notices

Operator Responsibility Warning

Highlights the operator's responsibility for safe boat operation.

California Emissions Warning

Provides a warning related to California emissions standards.

Section 1 - Warranty

Warranty Registration in North America

Process for registering warranty in the US and Canada.

International Warranty Registration

Process for registering warranty outside North America.

Warranty Transfer Procedure

How to transfer warranty to a subsequent owner.

Mercury Product Protection Plan Details

Information on the optional protection plan in North America.

Mercury MerCruiser Limited Warranty (Gasoline-Fueled Products)

Warranty Coverage Scope

Specifies what the limited warranty covers.

Warranty Duration Details

Outlines warranty periods for different models and use.

Recreational Use Warranty Period

Defines warranty duration for recreational applications.

Commercial Use Warranty Period

Defines warranty duration for commercial applications.

Warranty Coverage Conditions and Procedures

Mercury Marine's Warranty Obligations

Details Mercury Marine's responsibilities under the warranty.

Procedure for Obtaining Warranty Service

Steps to follow when seeking warranty service.

Exclusions from Limited Warranty

Lists items and conditions not covered by the warranty.

3-Year Limited Warranty Against Corrosion

Corrosion Warranty Coverage

Details what the 3-year corrosion warranty covers.

Corrosion Warranty Duration

Specifies the duration of the corrosion warranty.

Conditions for Corrosion Warranty

Requirements to obtain corrosion warranty coverage.

4-Year Limited Corrosion Warranty: SeaCore Models

SeaCore Corrosion Warranty Coverage

Details coverage for SeaCore models against corrosion.

SeaCore Corrosion Warranty Duration

Specifies the duration of the SeaCore corrosion warranty.

Global Warranty Charts Overview

Consumer Application Warranty Chart

Warranty coverage based on region and boat brand for consumers.

Commercial Application Warranty Chart

Warranty coverage based on region and boat brand for commercial use.

California Emissions Limited Warranty

Customer Warranty Rights and Obligations

Explains customer rights and responsibilities for emissions warranty.

Emission Control Parts Warranty Coverage

Details warranty coverage for emission control system components.

Emissions Warranty Details

Emissions Warranty Duration of Coverage

Specifies the duration of the California emissions warranty.

Procedure for Emissions Warranty Coverage

Steps to obtain warranty service for emissions issues.

Mercury's Emissions Warranty Actions

Details Mercury's obligations for emissions warranty claims.

Emissions Warranty Exclusions

Lists items not covered by the emissions warranty.

Emission Control System Components

Fuel Metering System Components

Lists components of the fuel delivery system.

Air Induction System Components

Lists components of the air intake system.

Ignition System Components

Lists components of the ignition system.

Disclaimers and Limitations

Mercury Installation Quality Certification Program

Details the certification program for installers and its benefits.

California Emission Control Warranty Statement

Customer Warranty Rights and Obligations

Explains customer rights and responsibilities for emissions warranty.

Manufacturer's Emission Warranty Coverage

Details warranty coverage for emission control parts.

Owner's Warranty Responsibilities

Outlines owner's duties for maintaining emissions warranty.

Section 2 - Getting to Know Your Power Package

Product Identification Information

Details on identifying engine and sterndrive components.

Engine Serial Number Decal Location

Locates the serial number decal on the engine.

Bravo Sterndrive Serial Number and Identification

Details for Bravo sterndrive serial number and identification.

Identification Details

Bravo Sterndrive Serial Number Stamping

Location of serial number stamping on the sterndrive casting.

Bravo Transom Serial Number Location

Location of the transom serial number on the U-bolt plate.

Lanyard Stop Switch Operation

Lanyard Stop Switch Functionality

Explains the purpose and function of the lanyard stop switch.

Situations Prone to Accidental Ejections

Identifies conditions likely to cause accidental ejections.

Instrumentation and Gauges

Digital Gauges Overview

Description of SmartCraft digital gauge features.

SmartCraft Instrument Features

SmartCraft Instrument Package Functionality

Functionality of SmartCraft package for diagnostics.

Analog Gauges Explanation

Analog Gauge Reference Table

Explanation of analog gauges and their functions.

Remote Controls (Non-DTS Models)

Panel Mount Remote Control Features

Details features of panel-mounted remote controls.

Neutral Lock Button Function

Explains the function of the neutral lock button.

Throttle Only Button Function

Explains the function of the throttle-only button.

Console Mount Remote Control Features

Console Mount Throttle Only Button

Function of throttle-only button on console mounts.

Control Handle Operation

Operation of control handles for shift and throttle.

Zero Effort Control Features

Zero Effort Shift Lever Operation

Operation of the shift lever in Zero Effort controls.

Zero Effort Throttle Lever Operation

Operation of the throttle lever in Zero Effort controls.

Remote Controls (DTS Models)

DTS Remote Control Introduction

Introduction to Digital Throttle and Shift (DTS) remote controls.

DTS Remote Control Features

DTS Panel Mount Features

Features of DTS panel mounted remote controls.

DTS Lanyard Stop Switch Function

Function of the lanyard stop switch in DTS systems.

DTS Control Handle Operation

Operation of the control handle in DTS systems.

Single Engine Console Mount Controls

Single Engine Control Handle Operation

Operation of the control handle for single engine console mounts.

Trim/Tilt Switch Function

Function of the trim/tilt switch on console mounts.

Slim Binnacle Console Mount Features (Single Engine)

Slim Binnacle Control Handle Operation

Operation of the control handle on slim binnacle mounts.

Stop/Start Button Function

Function of the stop/start button.

Dual Engine Console Mount Controls

Dual Engine Control Handle Operation

Operation of control handles for dual engine console mounts.

Active Light Indicator Function

Indicator for the active remote control station.

Synchronizing Dual Engines

Auto Synchronizing Feature Explanation

How the auto synchronizing feature works for dual engines.

Dual Helm Station Transfer

Procedure for Station Transfer

Steps for transferring helm control between stations.

Power Trim System

Power Trim Functionality

How power trim adjusts sterndrive angle.

Sterndrive Trim Up/Out Effects

Effects of trimming the sterndrive unit up or out.

Sterndrive Trim Down/In Effects

Effects of trimming the sterndrive unit down or in.

Single Engine Trim and Trailer Operation

Single Engine Trim Button Operation

How to use the trim button for single engines.

Trim Delta Functionality

Trim Delta Control Explanation

Controls angle difference between drives for trimming.

Electrical System Overload Protection

Circuit Breaker Functionality

How circuit breakers protect the electrical system.

Fuse Locations Identification

Identifies the locations of various fuses in the system.

Audio Warning System

Warning Horn Activation Conditions

Conditions that trigger continuous or intermittent horns.

Audio Warning System Testing Procedure

Procedure to test the functionality of the audio warning system.

Engine Guardian System

Engine Guardian Monitoring Parameters

Sensors monitored by the Engine Guardian system.

Section 3 - On the Water

General Safe Boating Suggestions

General advice for safe boating practices.

Passenger Safety During Boarding

Safety precautions for passengers during boarding.

Safe Boating Practices

Personal Flotation Device Usage

Importance and requirements for personal flotation devices.

Avoiding Boat Overloading

Guidance on understanding and adhering to boat load capacities.

Carbon Monoxide Poisoning Awareness

Symptoms of Carbon Monoxide Poisoning

Identifies symptoms of carbon monoxide poisoning.

Maintaining Good Ventilation

Recommendations for ensuring adequate ventilation.

Poor Ventilation Scenarios

Poor Ventilation When Stationary

Examples of poor ventilation when the boat is stationary.

Poor Ventilation When Moving

Examples of poor ventilation when the boat is moving.

Basic Boat Operation (Non-DTS Models)

Launching and Boat Operation Guidelines

Guidelines for launching and operating the boat.

Operation Chart

Pre-Operation Checks

Checks and procedures to perform before starting the engine.

Post-Start Checks

Checks and procedures to perform after starting the engine.

Starting and Stopping the Engine

Engine Starting Procedure

Step-by-step guide for starting the engine.

Cooling Water Supply Notice

Importance of adequate cooling water supply during operation.

Engine Starting Procedures

Standard Engine Starting Steps

Detailed steps for starting the engine.

Troubleshooting Engine Start Failures

Steps for when the engine fails to start.

Stopping the Engine

Engine Stopping Methods

Details various methods to stop the engine.

Throttle-Only Operation

Activating Throttle-Only Mode

Procedure for activating throttle-only mode.

Trailering the Boat

Sterndrive Position for Trailering

Options for sterndrive position during trailering.

Section 4 - Specifications

Fuel Requirements

Recommended gasoline types and octane ratings.

Engine Oil Recommendations

Recommended engine oil type and specifications.

Fluid Specifications

Engine Oil Capacity and Type

Details on engine oil capacity and recommended fluid type.

Bravo Sterndrives Fluid Capacities

Fluid capacities for Bravo sterndrive models.

Steering and Trim Fluid Specifications

Approved Power-Assisted Steering Fluids

Lists recommended fluids for power-assisted steering.

Approved Power Trim Fluids

Lists recommended fluids for power trim systems.

Section 5 - Maintenance

Owner and Operator Maintenance Responsibilities

Outlines owner's duties for safe operation and maintenance.

Dealer Maintenance Responsibilities

Details dealer's responsibilities for customer service.

Maintenance Procedures

DIY Maintenance Suggestions

Tips and suggestions for performing maintenance yourself.

Power Package Inspection Guide

Guidance on inspecting the power package for issues.

Sterndrive Maintenance Schedule

Routine Maintenance Tasks

Daily and weekly maintenance tasks for sterndrives.

Scheduled Maintenance Tasks

Periodic maintenance tasks based on hours or time intervals.

Engine Oil Maintenance

Engine Oil Checking Procedure

Procedure for checking the engine oil level.

Engine Oil Filling Procedure

How to correctly add engine oil.

Changing Engine Oil and Filter

Easy Engine Oil Drain System Instructions

Instructions for using the easy engine oil drain system.

Engine Oil Drain Pump Usage

Instructions for using the engine oil drain pump.

Power-Assisted Steering Fluid Maintenance

Checking Power-Assisted Steering Fluid Level

Procedure for checking the power-assisted steering fluid level.

Filling Power-Assisted Steering Fluid

How to add power-assisted steering fluid.

Engine Coolant Maintenance

Checking Engine Coolant Level

Procedure for checking the engine coolant level.

Filling Engine Coolant

How to add engine coolant.

Sterndrive Gear Lube Maintenance

Checking Sterndrive Gear Lube Level

Procedure for checking the sterndrive gear lube level.

Filling Sterndrive Gear Lube

How to add sterndrive gear lube.

Section 6 - Storage

Cold Weather or Extended Storage Procedures

Recommendations for storing the boat in cold weather or extended periods.

Power Package Preparation for Storage

Steps to prepare the power package for storage.

Engine and Fuel System Preparation for Storage

Fuel Tank Preparation for Storage

How to prepare fuel tanks for storage.

Draining the Seawater System

Drain System Identification

Identifies the type of drain system installed on the power package.

Air Actuated Single Point Drain System Procedure

Procedure for draining the system using an air-actuated method.

Manual Drain System Procedures

Draining Boat in the Water (Manual System)

Procedure for draining the manual system while the boat is in water.

Draining Boat Out of Water (Manual System)

Procedure for draining the manual system while the boat is out of water.

Draining the Sterndrive

Sterndrive Water Drain Hole Identification

Identifies sterndrive water drain and vent holes.

Battery Storage Guidelines

Recommendations for Battery Storage

Guidelines for storing batteries during extended periods.

Power Package Recommissioning

Pre-Start Checks After Storage

Essential checks before starting the engine after storage.

Section 7 - Troubleshooting

Diagnosing EFI Problems

Steps for diagnosing Electronic Fuel Injection (EFI) system issues.

Diagnosing DTS Problems

Steps for diagnosing Digital Throttle and Shift (DTS) system issues.

Engine Guardian System

Engine Guardian Monitoring Parameters

Sensors monitored by the Engine Guardian system for protection.

Troubleshooting Charts

Starter Motor Issues

Possible causes and remedies for starter motor problems.

Engine Start Failure

Possible causes and remedies for engine start failures.

Engine Performance Issues

Rough Running, Misfires, or Backfires

Causes and remedies for rough engine operation.

Clogged Fuel Filter Troubleshooting

Cause and remedy for a clogged fuel filter.

Fuel Contamination Troubleshooting

Cause and remedy for stale or contaminated fuel.

Performance and Engine Issues

Poor Performance - Throttle Issues

Cause and remedy for incomplete throttle opening.

Poor Performance - Propeller Issues

Cause and remedy for damaged or improper propeller.

Engine Overheating Issues

Excessive Engine Temperature - Water Inlet/Seacock

Cause and remedy for closed water inlets or seacocks.

Excessive Engine Temperature - Drive Belt

Cause and remedy for a loose or worn drive belt.

Insufficient Engine Temperature

Insufficient Temperature - Faulty Thermostat

Cause and remedy for a faulty thermostat.

Low Engine Oil Pressure Issues

Low Oil Pressure - Insufficient Crankcase Oil

Cause and remedy for insufficient oil in the crankcase.

Low Oil Pressure - Oil Quality Issues

Cause and remedy for diluted or improper viscosity oil.

Battery Charging Issues

Battery Not Recharging - Current Draw

Cause and remedy for excessive current draw from the battery.

Battery Not Recharging - Alternator Belt

Cause and remedy for alternator belt issues.

Remote Control Operation Issues

Remote Control - Lubrication Issues

Cause and remedy for lubrication issues on linkages.

Remote Control - Obstruction Issues

Cause and remedy for obstructions in linkages.

Steering System Issues

Steering Difficulties - Fluid Level

Cause and remedy for low power steering fluid level.

Steering Difficulties - Fluid Contamination

Cause and remedy for contaminated power steering fluid.

Power Trim - Motor Not Operating

Power Trim Failure - Blown Fuse

Cause and remedy for a blown power trim fuse.

Power Trim Failure - Electrical Connections

Cause and remedy for electrical connection issues.

Power Trim - Motor Operates, Unit Does Not Move

Trim Unit Inoperative - Low Oil Level

Cause and remedy for low trim pump oil level.

Trim Unit Inoperative - Binding in Gimbal Ring

Cause and remedy for drive unit binding in the gimbal ring.

Section 8 - Customer Assistance Information

Owner Service Assistance

Information on obtaining service for your Mercury MerCruiser product.

Local Authorized Dealer Repair Service

How to find authorized local repair services.

Service Assistance When Away From Home

Locating Nearest Service Center

How to locate service when away from your local dealer.

Reporting a Stolen Power Package

Actions to take if your power package is stolen.

Attention Required After Submersion

Pre-Recovery Contact with Dealer

Contacting dealer before recovering submerged equipment.

Post-Recovery Service Importance

Need for immediate service after equipment submersion.

Replacement Service Parts Information

Importance of Using Genuine Parts

Emphasizes using correct, genuine Mercury Marine replacement parts.

Parts and Accessories Inquiries

Ordering Parts and Accessories

Process for inquiring about and ordering parts and accessories.

Resolving Product Issues

Dealer Assistance for Problem Resolution

Steps for resolving issues through the dealership.

Mercury Marine Service Office Contact

Contact information for Mercury Marine service offices.