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Page i© 2005 Mercury Marine90-864840050 FEBRUARY 2005
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet,K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo,and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protectionlogo is a registered service mark of Brunswick Corporation.
 
STERNDRIVE MODELSGASOLINE ENGINE INSTALLATION MANUAL
Models CoveredBravo
Models CoveredSerial Number
496 Mag0W310000 and Above496 Mag DTS496 Mag HO496 Mag HO DTS
Notice
NOTICEAfter completing installation, these instructions should be placed with the product for theowner's future use.NOTICEPredelivery preparation instructions must be performed before delivering boat to theproduct owner.
Notice to Boat Manufacturer/Installer
Throughout this publication, Warnings and Cautions (accompanied by the InternationalHazard Symbol ) are used to alert the manufacturer or installer to special instructionsconcerning a particular service or operation that may be hazardous if performed incorrectlyor carelessly. ‑‑
Observe Them Carefully!
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict complianceto these special instructions when performing the service, plus common sense operation,are major accident prevention measures.
!
WARNING
WARNING ‑ indicates a potentially hazardous situation that, if not avoided, could resultin death or serious injury.
!
CAUTION
CAUTION ‑ indicates a potentially hazardous situation that, if not avoided, may result inminor or moderate injury or property damage. It may also be used to alert against unsafepractices.
 
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IMPORTANT: Indicates information or instructions that are necessary for properinstallation and/or operation.
NOTE:
Refer to the appropriate Mercury MerCruiser Product Applications Manual for application recommendations.
This installation manual has been written and published by Mercury MerCruiser to aid theboat manufacturer (OEM) in the installation of the products described herein.It is assumed that these personnel are familiar with marine product installation.Furthermore, it is assumed that they are familiar with, if not trained in, the recommendedinstallation procedures of Mercury MerCruiser product.We could not possibly know of or advise the marine trade of all conceivable installationsand of the possible hazards and/or results of each installation. Therefore, the OEM isresponsible for any installation that does not fulfil the requirements of this manual.It is the responsibility of the boat manufacturer to select the appropriate engine/transom/drive package (including the correct gear ratio and propeller) for a given boat. MercuryMerCruiser recommends that any new or unique hull/power package combination bethoroughly water tested prior to sale, to verify that the boat performs as desired, and thatthe engine operates in the appropriate RPM range.It is recommended that a Mercury MerCruiser Product Application Engineer (PAE) becontacted for assistance. For assistance outside the United States, contact the localMercury Marine office or authorized distributor. All information, illustrations and specifications contained in this manual are based on thelatest product information available at time of publication. Mercury Marine reserves theright to make changes at any time without obligation. As required, revisions to this manualwill be sent to all OEM boat companies.
 
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Manual Outline
1 - Important Information2 - Boat Construction3 - Exhaust System4 - Fuel System5 - Cooling System6 - Drive System and Engine Mounting7 - Starting And Electrical8 - Remote Controls9 - Predelivery Preparation and Storage
Important Information
1
Boat Construction
2
Exhaust System
3
Fuel System
4
Cooling System
5
Drive System and Engine Mounting
6
Starting And Electrical
7
Remote Controls
8
Predelivery Preparation andStorage
9
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