496 HO Sport Instructions
Contents
1. 2 19892 Hose Plugs 94 X 3 2 Stainless Steel Round 496 Hardware Components Kit 41042 Located in the relocation kit box QTY PART DESCRIPTION MATERIAL 2 38206 5 16 18 X 5 8 Flange Bolt Carbon Steel 3 38207 6 1 00 X 10 Flange Bolt Carbon Steel 2 38208 1 00 Flange Nut Carbon Steel 1 38209 M6 1 00 X 12 Flange Bolt Carbon Steel 3 38211 6 1 00 X 130 SHCS Zink Plated Carbon 1 38212 1 2 X 1 2 Roll Pin Stainless Steel Assembles into Swifter Bracket 2 36090 12 Hose Clamps Stainless Steel 2 38495 Screws Fuel Pump M8 1 25 X 50 Carbon Steel 1 Assembly Instruction Packet White Paper Envelope Tailpipes 39053 Located in the relocation kit box QTY PART DESCRIPTION 2 Special 496 Tailpipe Clamp Kit 36270 Located in the relocation kit box QTY PART DESCRIPTION 2 36270 Sweeper Flex Flare Clamp Kits hoses clamps gaskets K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 8 HEADERS TAILPIPES CLAMPS amp DIST TUBES ILLUSTRATION 2 HEADER ASSEMBLY STARBOARD HEADER 14144 37053 HEADER ASSEMBLY PORT HEADER 13143 me Lo m a gre 2 ae DISTRIBUTION TUBE ASSEMBLY 30140 PORT amp STARBOARD K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructio2. 2012 Page 2 SALES 496 HO 961 v kit 496 13162 13 6 15 2012 3 CMI 13162 Polish Finish TABLE OF CONTENTS 3D OVERVIEW OF 496 ENGINE 4 OVERVIEW OF PARTS SUPPLIED BY PAGE 5 496 HO COMPONET INDEX 6 HEADERS TAILPIPES CLAMP DIST TUBES 7 WATER FLOW DIAGRAM SEA WATER OIL FILTER BRACKET ILLUSTRATIONS 8 SWIFTER PLATE ILLUSTRATIONS COMPONENT PLATE ILLUSTRATIONS PAGE 9 FUEL PUMP ILLUSTRATIONS COMPONENT REMOVAL amp INSTALLATION PAGES 10 17 STEP BY STEP INSTRUCTIONS IMPORTANT PAGE 19 DIVERTER ADAPTER INSTALLATION PAGES 20 23 STEP BY STEP INSTRUCTIONS IMPORTANT PAGE 24 K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 4 ABOVE ITEMS HIGHLIGHTED IN RED ARE FURNISHED BY CUSTOM MARINE INC ALLOW FOR THE STAINLESS STEEL EXHAUST HEADERS IN SOME CASES COMPONENTS WILL HAVE ENOUGH CLEARANCE WITHOUT CHANGING OR ADDING BRACKETS DUE TO THE YEAR YOUR ENGINE WAS BUILT K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions 13 doc 6 15 2012 Page 5 CMI Supplied Parts Overview K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 6 K SALES 496 HO MAG 496 new kit 496 13162 Instructions rev 13 doc 6 15 2012 Page 7 496 Sport Tube Performance Package Component Index Port Si
3. E Picture P3 STEP 9 DISCONNECT OIL FILTER LINES AT FILTER HOUSING USE CONTAINER TO CAPTURE OIL STEP 10 REMOVE 4 NUTS FROM STUDS THAT SECURE ECU BRACKET TO INTAKE amp EXHAUST MANIFOLD Toe TT all s K SALES 496 96 new kit 496 HO 13162 Instructions 13 doc 6 15 2012 14 STEP 11 LIFT BRACKET FROM STUDS TO PROVIDE FOR LOG MANIFOLD REMOVAL STEP 12 REMOVE 2 COOLANT HOSES FROM BOTTOM OF LOG MANIFOLD AND PLUG LOWER LINE AS SHOWN IN PICTURE P1 REMOVE 8 LOG MANIFOLD ATTACHING BOLTS REMOVE LOG MANIFOLD BEING CAREFUL NOT TO BREAK SPARK PLUGS OR WIRE BOOTS STEP 13 REMOVE amp SAVE 3 ECU MOUNTING BOLTS FANNA fon lh ANT AB SPRAY 2 222 8 F STEP 14 PLACE ECU ASIDE ON TOP OF INTAKE MANIFOLD TO LOCATION SHOWN CAREFULLY REMOVE 3 ELECTRICAL RELAYS FROM BRACKET WITH FLAT BLADE SCREWDRIVER FLIP BRACKET OVER TO REMOVE RESET BREAKER amp SOLENOID SAVING HARDWARE FOR REUSE POSITION ALL PREVIOUSLY REMOVED ELECTRICAL COMPONENTS DOWN TO PROVIDE FOR INSTALLATION OF CMI ECU BRACKET STEP 15 MOUNT CMI ECU BRACKET REUSING SHOULDER NUT ON PREVIOUSLY USED STUD LOCATED ON REAR OF INTAKE MANIFOLD USE SUPPLIED BOLT TO MOUNT BRACKET TO FRONT OF INTAKE MANIFOLD AS SHOWN IN PICTURE P4 STEP 16 FLIP ECU OVER amp MOUNT TO CMI BRACKET REUSING M
4. E CONNECTIONS FOR POSSIBLE LEAKS BEFORE USING IMPORTANT FIRST RUN FOR 10 MINUTES ALLOW ENGINE TO COOL CHECK HEADER BOLTS FOR TIGHTNESS K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 21 OO ADAPTER Il CMI Diverter Installation with CMI 496 Performance Package After removal of stock exhaust and installation of your new CMI 496 Performance Package headers continue as follows for diverter installation 1 Layout your CMI diverter adapter items to verify that all necessary hardware is included Note Diverters are customer supplied and not included in kit 2 Metal Adapter Rings 4 O Rings 4 Band Clamps 2 Adapters Picture 1 K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions 13 doc 6 15 2012 Page 22 2 Pre assembly of the adapter kit and the diverter a Apply lubricant such as dish soap to diverter and slide on metal ring as shown picture 2A b Slide O ring on as shown in picture 2B Picture 2A Picture 2B c Install band clamp around the metal ring and o ring but do not tighten d Slide CMI adapter into place as shown in picture 2D making sure clamp is completely capturing metal ring o ring and CMI adapter Picture 2C Picture 2D K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 23 3 Install header band clamp and gasket into place as show
5. OUNTING BOLTS FROM STOCK PLATE MOUNT RESET BREAKER USING SAVED HARDWARE MOUNT SOLENOID USING SUPPLIED HARDWARE AS SHOWN IN PICTURE P5 STEP 17 MOUNT 3 ELECTRONIC RELAYS BY CAREFULLY PRESSING INTO AS SHOWN IN PICTURE P5 NOTE WIRE HARNES MAY NEED TO BE CUT BACK AND RE TAPED CAUTION BECAREFUL NOT TO CUT EXPOSED WIRES a AA Picture P4 Picture 5 K SALES 496 96 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 15 BEFORE AFTER K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 16 REMOTE OIL FILTER ASSEMBLY A RE USE OLD O RING AND FITTING LUBRICATE FLAT O RING WITH MOTOR OIL AND INSTALL IN RECESSED AREA IN OIL FILTER ADAPTOR WITH THREADED LINE FITTING AS SHOWN IMPORTANT FLAT O RING MUST BE PROPERLY SEATED IN OIL FILTER HOUSING TO PREVENT LEAKS INSPECT TO ENSURE ALL HOSES ARE PROPERLY SEATED B MOUNT OIL FILTER HOUSING TO BRACKET WITH 2 PROVIDED BOLTS MOUNT THE CLIP BRACKET TO MAIN BRACKET USING THE 2 SCREWS REMOVED FROM THE ORIGINAL IIE fl el Fl LELE POWER STERIMG RES K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 17 STEP 18 REMOVE AIR CONTROL BRACKET BY REMOVING 2 NYLOCK NUTS FROM ST
6. Page Custom Marine STAINLESS EXHAUST Thank you for purchasing the 496 Sport Tube Performance Package The relocation kit components in this package are designed to cover the many variations for both the 496 HO and Mag series In many cases brackets and components in the relocation kit may not be required or may need to be positioned differently than illustrated in the instruction manual to work in your specific model year application Dont be afraid to modify or re adjust the components for compatibility that suits your requirement It is Custom Marine s intent to supply everything necessary to make the installation as easy as possible The relocation kit contains the parts needed to overcome most obstructions In some applications modifications to the relocation component may be necessary to accommodate a particular function or clearance issue Similarly for those of you using the diverter adapter version of this kit the adapters are designed to fit MOST versions of Corsa diverters but in no way accommodates all the variations currently in use Custom Marine is constantly seeking ways to improve our products to better serve you our customer Therefore as new model year discrepancies emerge we will continue making adjustment to the package Please let us know if you encounter any issues during installation Thank you again for your patronage K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15
7. R STEP 2 REMOVE 2 COOLANT HOSES FROM BOTTOM OF LOG MANIFOLD PLUG LOWER HOSE AND CLAMP AS SHOWN IN PICTURE P1 gt te A ra M WQ 154 Picture 1 STEP 3 REMOVE 1 SHIFT BRACKET BOLT FROM OF LOG MANIFOLD STARBOARD SIDE STEP 4 IMPORTANT REMOVE HEAT SENSORS ON BOTH MANIFOLDS FIRST REMOVE 8 LOG MANIFOLD BOLTS REMOVE LOG MANIFOLD WHILE BEING CAREFUL NOT TO BREAK SPARK PLUGS OR RUBBER BOOTS CLEAN GASKET SURFACE ON MOTOR K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 12 STEP 5 REMOVE SHIFTER BRACKET MOUNTING BOLTS DO NOT REMOVE SHIFT CABLE OR WIRE HARNESS CONNECTOR BE CAREFUL NOT TO DROP SPACERS REMOVE BRACKET STEP 6 REMOVE 2 SHIFT PLATE MOUNTING BOLTS FROM BRACKET ON REAR OF ENGINE AND REMOVE BRACKET STEP 7 INSTALL CMI SHIFT PLATE REUSING REAR MOUNTING BOLTS USE SUPPLIED SHOULDER NUT TO MOUNT TO STUD ON INTAKE MANIFOLD REMOUNT SHIFT BRACKET WITH ATTACHED CABLES REUSING SAME HARDWARE AS WAS USED ON STOCK SHIFT PLATE MOUNT AS SHOWN IN PICTURE P2 K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 13 REMOTE OIL FILTER ECU BRACKET REMOVAL INSTALLATION PORT SIDE STEP 8 REMOVE 3 RESERVOIR BRACKET BOLTS amp REMOVE FORK BRACKET amp T STRAP FORK BRACKET WILL BE REUSED AS SHOWN IN PICTUR
8. UDS ON FRONT OF ENGINE INSTALL REMOTE FILTER BRACKET ON THESE STUDS FOLLOWED BY THE AIR CONTROL BRACKET amp 2 NYLOCK NUTS AS SHOWN IN PICTURE P6 AND P7 ES AAT SAE Picture P6 STEP19 REINSTALL RESERVOIR ON FORK BRACKET 4 HOSE AT BOTTOM SHOWN IN PICTURE P7 Picture P7 K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 18 STEP 20 REMOVE FUEL PUMP AND REINSTALL WITH NEW BRACKET 28968 AND SPACER 50920 AS SHOWN IN PICTURE P8 854650 5 017 SAE J1171 MARINE 0546 Picture P8 STEP 21 INSTALL CMI HEADERS PER MERCURY RACING SERVICE MANUAL PROTOCOL ADJUST LENGTH OF COOLING HOSES TO FIT DISTRIBUTION TUBE ON HEADERS SEE PICTURES P9 AND P10 FOR HEADER INSTALL REFERENCE STEP 22 INSTALL INTAKE MANIFOLD COVER USING 3 SPACERS amp LONGER SCREWS PROVIDED STEP 23 INSTALL HEAT SENSORS 2 INHEADER COLLECTOR BUNG STEP 24 INSTALL TAILPIPES WITH CLAMP AND GASKETS INSTALL JUMPER HOSES BETWEEN HEADER AND TAILPIPES WITH CLAMPS STEP 25 ATTACHED TAILPIPES WITH CUSTOMER SUPPLIED HOSE AND CLAMPS TO TRANSOM TIPS sS OCD AM K SALES 496 HO MAG 496 new kit 496 13162 Instructions rev 13 doc 6 15 2012 Picture 10 K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 IMPORTANT START ENGINE AND CHECK ALL HOS
9. de Header amp Assembly Components in each Box 1 13163 Port Side Down Turned Sport Tube Header 1 19890 Heat Sensor Bungs Installed in the Headers 1 34160 Head Gaskets 8 38490 Metric Header Bolts 1 30140 Stainless Steel Distribution Tubes Kit Number 41016 32030 31 0 X 90 degree Hose for Distribution Tubes 86020 8 Hose Clamps 36090 12 Hose Clamps 19580 75 NPT X 1 X 90 Degree Fitting 19650 75 NPT X 1 X Straight Fitting Starboard Side Header amp Assembly Components in each Box 13164 Starboard Side Down Turned Sport Tube Header 19890 Heat Sensor Bungs Installed in the Headers 34160 Head Gaskets 38490 Metric Header Bolts 4 8 1 1 1 30140 Stainless Steel Distribution Tubes 32030 X 90 degree Hose for Distribution Tubes Kit Number 41016 8 36020 8 Hose Clamps 1 36090 12 Hose Clamps 1 19580 75 NPT X 1 X 90 Degree Fitting 1 19650 75 NPT X 1 X Straight Fitting Relocation Kit 41041 496 Components Kit 41040 QTY PART DESCRIPTION MATERIAL 1 28965 Swifter Bracket HRPO Coated Black 1 28966 Comp Bracket 10 Ga HRPO Coated Black 1 28952 Oil Filter Bracket Y4 Coated Black 1 50920 Fuel Pump Spacer 1 00 X 4 3 4 SQ Aluminum 1 28968 Fuel Pump Bracket 10 Ga HRPO Coated Black 1 50921 Oil Filter Spin On Aluminum 3 29980 Offset Spacer 50 X 25 Wall CRS Tube 2 625 lg
10. n in picture 3 Do not tighten 4 Slide rubber bull horn hose all the way down as in picture 4 note you must loosen clamps If necessary remove completely and put soap around bull horn and reassemble Insert preassembly onto bull horn as in picture 4 Picture 3 Picture 4 5 Push adapter end of preassembly into header clamp see picture 5 Note sometimes it may be necessary to loosen header clamp screw completely 6 Slide rubber bull horn hose onto diverter see picture 6 and tighten per factory specifications _ 1 4 s 9 2 K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 Page 24 Picture 5 Picture 6 7 Tighten band clamp between header and adapter then tighten band clamp between the diverter and adapter Tighten per factory specifications 8 Install rubber jumper hose and tighten clamps see picture 7 Picture 7 9 Attach diverter to the transom tip as previously installed 10 Repeat the same steps for the opposite side IMPORTANT START ENGINE AND CHECK ALL HOSE CONNECTIONS FOR K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions 13 doc 6 15 2012 Page 25 POSSIBLE LEAKS BEFORE USING IMPORTANT FIRST RUN FOR 10 MINUTES ALLOW ENGINE TO COOL CHECK HEADER BOLTS FOR TIGHTNESS K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012
11. ns rev 13 doc 6 15 2012 IEE d POWER STERING RES N ERBIING BRACKET SWIFTER PLATE ILLUSTRATION A 4 POWER STEERING ACTUATOR REMOUNT TO NEW PLATE EXISTING LINKAGE BAR REUSE EXISTING FASTENERS SWIFTER PLATE RELOCATION SWIFTER PLATE 28985 ON ENGINE BLOCK NOT REMOVE K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 10 COMPONENT PLATE ILLUSTRATION 5 RE OLEH OID TA HD 28 LUS PLATE PLUG ADAPTER CONNECTORS 2 PLA ES RELBE FASTENER RENO LHT RESET BREA KER COMPONENT PLATE 2287 66 RELBE FASTENER Se BRAC KET STYLE AY VARY PER YEAR CLASS 1 122 LHT EC LILHIT TO PLATE LEIH G EXBTING FASTEN ERS COMPONENT PLATE RELOCATION FUEL PUMP PLUG ILLUSTRATION 6 EXBTING BRACKET 269 1 ATTA CHED LHT 325475 WE 125 30 BOLTS TO FARSIDE F PVP 4 EXBTING FUEL PUVP BRACKET 4257 PLUG 2219592 HOSE CLA UP 22 2 10 LUS BITH PORTAND STARBOARD SIDE FUEL PUMP RELOCATION amp PLUG INSTRUCTIONS BRACKETS WAY HOT BE INC LLDED FOR YOUR TEAR CLASS ENGINE K SALES 496 HO MAG 496 new kit 496 HO 13162 Instructions rev 13 doc 6 15 2012 11 STEP STEP COMPONENT REMOVAL AND INSTALLATION STEP 1 REMOVE ENGINE COVE
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