ELECTRICAL SYSTEMS 4 D WIRING DIAGRAMS

Transcription

1 EECRICA SYSEMS 4 D 798 WIRING DIAGRAMS

2 able of Contents Page Wiring Colors for MerCruiser D- Wire Color Abbreviations D- Wiring Diagrams D- MCM./.X D- MCM V-6 Alpha Drive Engines D- MCM V-8 Alpha Drive Engines D-4 MCM V-8 Bravo Drive Engines D-5 MIE V-8 All Inboard and Ski Engines D-6 MCM Quicksilver Instrumentation D-7 MIE Quicksilver Instrumentation D-8 Dual Station Wiring (Using a Neutral Safety Switch in Only one Remote Control) D-9 Dual Station Wiring (Using A Neutral Safety Switch In both Remote Controls) D- Dual Station Wiring (Using a Neutral Safety Switch in Engine Wiring Harness) D- Gauges D- Battery Meter Gauge D- Cruiselog D- Fuel Gauge and Sender D- Audio Warning System D- Water emperature Gauge D- Oil Pressure Gauge D- Clock D- Wiring Diagrams for 5 EFI D-5 EFI Wiring Diagram D-7 ECM Component Connector Charts D- 4D- - WIRING - DIAGRAMS

3 Wiring Colors for MerCruiser Black Brown Orange t. Blue/White Gray Green/White an t. Blue Pink Brown/White Purple/White Red Red/Purple Red/Purple Orange Purple/Yellow BIA Color Code All Grounds Where Reference Electrode-MerCathode Anode Electrode-MerCathode rim- Up Switch achometer Signal rim - Down Switch Water emperature Sender to Gauge Oil Pressure Sender to Gauge Fuel Gauge Sender to Gauge rim Sender to rim Gauge rim- railer Switch Unprotected Wires from Battery Protected (Fused) Wires from Battery Protected (+V) to rim Panel Alternator Output Ballast Bypass Purple Ignition Switch (+ V) Yellow/Red Wire Color Abbreviations Starter Switch to Starter Solenoid to Neutral Start Switch BU BRN GRN ORN PNK RED AN WH YE I DRK Black Blue Brown Gray Green Orange Pink Purple Red an White Yellow ight Dark WIRING DIAGRAMS - 4D-

4 Wiring Diagrams MCM./.X NOE : Gray lead for use with service tachometer. A -Ignition System -Distributor -Shift Cutout Switch -Filter 4 -Ignition Coil B -Starting System -Alternator -Electric Choke ( BB Only) -Ground Bolt 4 -Starter 5 -Circuit Breaker 6 -Starter Slave Solenoid C-Audio Warning System -Water emperature -Drive Unit Oil evel (If Equipped) -Oil Pressure Switch D -Instrumentation System -Oil Pressure Sender -Water emperature Sender -rim Sender 4D- - WIRING DIAGRAMS

5 MCM V-6 Alpha Drive Engines WH/RED WH/GRN A -Ignition System -Distributor -Shift Cutout Switch -erminal Block 4 -Ignition Coil B -Starting System -Alternator -Electric Choke ( BB Only) -Ground Bolt 4 -Starter 5 -Circuit Breaker 6 -Starter Slave Solenoid 7 -Fuel Pump C-Audio Warning System -Water emperature -Drive Unit Oil evel (If Equipped) -Oil Pressure Switch D -Instrumentation System -Oil Pressure Sender -Water emperature Sender -rim Sender WIRING DIAGRAMS - 4D-

6 MCM V-8 Alpha Drive Engines WH/RED WH/ GRN PU R A -Ignition System -Distributor -Shift Cutout Switch -erminal Block 4 -Ignition Coil B -Starting System -Alternator -Electric Choke ( BB Only) -Ground Bolt 4 -Starter 5 -Circuit Breaker 6 -Starter Slave Solenoid C-Audio Warning System -Water emperature -Drive Unit Oil evel (If Equipped) -Oil Pressure Switch D -Instrumentation System -Oil Pressure Sender -Water emperature Sender -rim Sender 4D-4 - WIRING DIAGRAMS

7 MCM V-8 Bravo Drive Engines WH/RED WH/GRN A -Ignition System -Distributor -Ignition Coil B-Starting and Charging Systems -Alternator -Ground Stud -Starter Motor 4 -Circuit Breaker 5 -Starter Slave Solenoid C -Audio Warning System -Water emperature -Drive Unit Oil evel (If Equipped) -Oil Pressure Switch D -Instrumentation System -Oil Pressure Sender -rim Sender -Water emperature Sender WIRING DIAGRAMS - 4D-5

8 MIE V-8 All Inboard and Ski Engines WH/ RED WH/ GRN GR Y PU R NOE : aped back brown and black wire may be used for an accessory. OAD MUS NO EXCEED 5 AMPS A-Ignition System -Distributor -Ignition Coil B -Starting and Charging System -Alternator -Ground Stud -Starer Motor 4 -Circuit Breaker 5 -Neutral Safety Switch 6 -StarterSlave Solenoid C -Audio Warning System -Water emperature -ransmission Fluid emperture -Oil Pressure D -Instrumention System -Oil Pressure Sender -Water emperature Sender 4D-6 - WIRING DIAGRAMS

9 MCM Quicksilver Instrumentation B S I NOE : Connect wires together with screw and hex nut. Apply Quicksilver iquid Neoprene to connection and slide rubber sleeve over connection. NOE : Power for a second fused accessory panel may be tasken from this connection. oad MUS NO exceed 5-4 amps. Panel ground wire MUS BE connected to instrument terminal that has an 8 gauge black (ground) harness wire connected to it. - achomter - Audio Warning Buzzer (if Equipped) - Oil Pressure 4 - Water emperature 5 - Battery Meter 6 - Ignition Switch 7 - rim Indicator 8 - o Volt Source (purple wire connection) 9 - Ampere Fuse WIRING DIAGRAMS - 4D-7

10 MIE Quicksilver Instrumentation B S I NOE : Connect wires together with screw and hex nut. Apply Quicksilver iquid Neoprene to connection and slide rubber sleeve over connection. NOE : Power for a second fused accessory panel may be tasken from this connection. oad MUS NO exceed 5-4 amps. Panel ground wire MUS BE connected to instrument terminal that has an 8 gauge black (ground) harness wire connected to it. - achomter - Audio Warning Buzzer (if Equipped) - Oil Pressure 4 - Water emperature 5 - Battery Meter 6 - Ignition Switch 7 - o Volt Source (purple wire connection) 8 - Ampere Fuse 4D-8 - WIRING DIAGRAMS

11 Dual Station Wiring (Using a Neutral Safety Switch in Only one Remote Control) A 4 5 GND SW UNSW V SIG GND GND GND V V V SEND SEND SEND YE/RED. BU AN NOE YE/RED NOE RED/ 4 5 BRN/WH 7 ORN B S I GND SW UNSW V SIG GND GND V V V SEND SEND SEND GND YE/RED. BU AN ORN RED/ NOE YE/RED NOE NOE B NOE NOE YE/RED YE/RED BRN/WH NOE : Brown/white wire is taped back at instrument end. If installing on boat that is equipped with MerCruiser Stern Drive, brown/white wire is connected to trim sender terminal block. If installing on MerCruiser Inboard, brown/white wire is taped back at engine end, or it may be used for an accessory (limit 5 amperes) NOE : An accessory fuse panel may be connected at this location. he combined current draw of the primary station and secondary station MUS NO exceed 5 amperes. NOE : Connect wires together with screw and hex nut. Apply Quicksilver iquid Neoprene to connection and slide rubber sleeve over connection. A - Secondary Station - Stop -Start Panel - achometer - Oil Pressure 4 - Water emperature 5 - Battery Meter B - Primary Station - Ignition Switch - achometer - Oil Pressure 4 - Water emperature 5 - Battery Meter 6 - o Engine 7 - Ampere Fuse WIRING DIAGRAMS - 4D-9

12 Dual Station Wiring (Using A Neutral Safety Switch In both Remote Controls) A 4 5 GND SW UNSW V SIG GND GND GND V V V SEND SEND SEND. BU AN YE/RED YE/RED NOE YE/RED NOE NOE RED/ 4 5 BRN/WH 7 B S I GND SWUNSW V SIG GND GND GND V V V SEND SEND SEND ORN YE/RED. BU AN ORN RED/ NOE 6 NOE YE/RED B YE/RED YE/RED NOE NOE BRN/WH YE/RED NOE NOE : Brown/white wire is taped back at instrument end. If installing on boat that is equipped with MerCruiser Stern Drive, brown/white wire is connected to trim sender terminal block. If installing on MerCruiser Inboard, brown/white wire is taped back at engine end, or it may be used for an accessory (limit 5 amperes) NOE : An accessory fuse panel may be connected at this location. he combined current draw of the primary station and secondary station MUS NO exceed 5 amperes. NOE : Connect wires together with screw and hex nut. Apply Quicksilver iquid Neoprene to connection and slide rubber sleeve over connection. 794 A - Secondary Station - Stop -Start Panel - achometer - Oil Pressure 4 - Water emperature 5 - Battery Meter B - Primary Station - Ignition Switch - achometer - Oil Pressure 4 - Water emperature 5 - Battery Meter 6 - o Engine 7 - Ampere Fuse 4D- - WIRING DIAGRAMS

13 Dual Station Wiring (Using a Neutral Safety Switch in Engine Wiring Harness) A 4 5 GND SW UNSW V SIG GND GND GND V V V SEND SEND SEND YE/RED. BU AN NOE YE/RED NOE RED/ 4 5 BRN/WH 7 B S I GND SW UNSW V SIG GND GND GND V V V SEND SEND SEND ORN YE/RED. BU AN ORN RED/ NOE 6 YE/RED NOE NOE B NOE BRN/WH YE/RED NOE NOE : Brown/white wire is taped back at instrument end. If installing on boat that is equipped with MerCruiser Stern Drive, brown/white wire is connected to trim sender terminal block. If installing on MerCruiser Inboard, brown/white wire is taped back at engine end, or it may be used for an accessory (limit 5 amperes) NOE : An accessory fuse panel may be connected at this location. he combined current draw of the primary station and secondary station MUS NO exceed 5 amperes. NOE : Connect wires together with screw and hex nut. Apply Quicksilver iquid Neoprene to connection and slide rubber sleeve over connection. 794 A - Secondary Station - Stop -Start Panel - achometer - Oil Pressure 4 - Water emperature 5 - Battery Meter B - Primary Station - Ignition Switch - achometer - Oil Pressure 4 - Water emperature 5 - Battery Meter 6 - o Engine 7 - Ampere Fuse WIRING DIAGRAMS - 4D-

14 Gauges Battery Meter Gauge a Fuel Gauge and Sender Note b c a - amp Mounting Hole b - Purple (or White) Jumper Wire from his erminal to I..... (or+) erminal on Water emperature or Oil Pressure Gauge c - Black Jumper Wire from his erminal to Ground erminal on Water emperature or Oil Pressure Gauge PNK PNK 786 Note Cruiselog a Note : Connect terminal to Ignition or Accessory erminal of Ignition. Note : Connect to Negative Battery erminal or Suitable Ground. - ank Sender - Sender Capsule Fuel Gauge (Black Case) b 785 a - Connect to Ignition Switch Volt Positive(+) Source (PE WIRE) b - Connect to Negative ( ) Ground (BACK WIRE) 4D- - WIRING DIAGRAMS

15 Audio Warning System Oil Pressure Gauge! WARNING Buzzer is not external ignition-proof; therefore, DO NO mount buzzer in engine or fuel tank compartments. 4 RED 789 AN/BU AN/BU - Ground (Black) - Switched Volt erminal (PE) - Sender ead (IGH BUE) - Audio Warning Buzzer - Water emperature Switch - Oil Pressure Switch 4 - Volt Power Source 787 Clock Water emperature Gauge Connect Wire (DARK BUE)to an Ignition erminal of an Adjacent Gauge or to Any Switched Volt erminal. - Connect to Instrument Harness (RED/PE) ead and Slide a Rubber Sleeve over the Connection. - Connect Wire (BACK) to a erminal on an Adjacent Gauge or to Another Suitable Ground Ground (Back) - Switched Volt erminal (PE) - Sender ead (AN) WIRING DIAGRAMS - 4D-

16 Quicksilver Instrumentation For 454 Magnum EFI Ski NOE : Connect wires together with screw and hex nut. Apply Quicksilver iquid Neoprene to connection and slide rubber sleeve over connection. NOE : Power for a second fused accessory panel may be tasken from this connection. oad MUS NO exceed 5-4 amps. Panel ground wire MUS BE connected to instrument terminal that has an 8 gauge black (ground) harness wire connected to it. - achomter - Audio Warning Buzzer (if Equipped) - Oil Pressure 4 - Water emperature 5 - Battery Meter 6 - Ignition Switch 7 - o Volt Source (purple wire connection) 8 - Ampere Fuse 4D-4 - WIRING DIAGRAMS

17 Wiring Diagrams for 5 EFI A B c 5 4 C b A - Audio Warning System - Oil Pressure Switch - Drive Unit Oil evel B - Instrumentation System - Oil Pressure Sender - Water emperature Sender - rim Sender C - Charging and Starting System - Alternator - Ground Stud - Starter 4 - Circuit Breaker 5 - Starter Slave Solinoid a - Positive Power Wire o EFI System Harness b - Harness Connector o EFI System Harness c - Auxiliary achometer ead a WIRING DIAGRAMS - 4D-5

18 Wiring Diagrams (Continued) - Vapor Separator ank (VS) - hrottle Body - Distributor 4 - Coil 5 - Electronic Spark Control (ESC) Module 6 - Assembly ine Data ink (AD) 7 - Manifold Absolute Pressure (MAP) Sensor 8 - Manifold Air emperature (MA) Sensor 9 - Knock Sensor -Idle Air Control (IAC) - hrottle Position Sensor (PS) -Coolant emperature Sensor (CS) -Electronic Control Module (ECM) 4 -Fuel Pump Relay) 5 -Ignition Relay 6 -Fuel Pump Fuse (5 Amp) 7 -Injector Fuse(5 Amp) 8 -ECM Fuse ( Amp 9 -Harness Connector to Starting/Charging Harness -Harness Connector to anyard Stop Switch (Optional) -Harness Connector for Dual Engine Data ink Cable -Positive (+) Power Wire to Engine Circuit Breaker = Black BU = Blue BRN = Brown GRN = Green = Gray ORN =Orange PNK = Pink = Purple RED = Red AN = an WH White YE = Yellow I = ight DRK = Dark NOE: All black wires with a ground symbol are interconnected within the EFI system harness. 769 MCM (Stern Drive) 454/5 MAGNUM EFI ENGINE SYSEM HARNESS 4D-6 - WIRING DIAGRAMS

19 EFI Wiring Diagram INJECORS,, 5, DK BU 5A INJECORS, 4, 6, 7 5A IDE AIR CONRO (IAC) VAVE 44 BU/WH 44 BU/ 44 GRN/ WH ININE CONNECOR (WIN ENGINE APPICAION ONY) C B A 444 GRN/ 96 YE J-5 MASER/SAVE 46 ORN/ O ECM FUSE A 44 ORN EFI Wiring Diagram ( of 4) WIRING DIAGRAMS - 4D-7

20 EFI Wiring Diagram ( of 4) 4D-8 - WIRING DIAGRAMS

21 ES MODUE B A EECRONIC SPARK IMING (ES) DIS. REFERENCE HIGH BYPASS DIS. REFERENCE OW O BUZZER AN/BU D AN O IGN O AUDIO WARNING SWICHES PP BU/AN C B PNK O ACH A WH COOAN OVEREMP (O BUZZER) OW OI PRESSURE/OW I/O FUID (O BUZZER) 9 BRN J-6 O OW OI PRESSURE AND GEAR UBE SWICHES EFI Wiring Diagram ( of 4) WIRING DIAGRAMS - 4D-9

22 SYSEM/IGNIION REAY O IGN COI ERM B O FUE PUMP REAY FUSE 5A O INJECORS 87 ECM BA FUSE 5A 5A 5A A B ANYARD SOP SWICH CIRCUI EFI Wiring Diagram (4 of 4) 4D- - WIRING DIAGRAMS

23 ECM Component Connector Charts he following charts is to aid in diagnosis of symptoms. hese voltages were derived from a known good engine. he voltages shown were done with the electrical system intact and operational. hese are voltage requirements to operate the different circuits.! CAUION Do not attempt to obtain these voltages by probing wires and connectors. Serious damage could result in loss of engine operation or wiring damage. Voltages can vary with battery conditions. J- J- Front Pin Pin Output Connector J- J- Rear Pin Pin Output Connector HESE NOES APPY O FOOWING ECM CONNECOR AND SYMPOMS CHARS. he B+ Symbol indicates a system voltage (battery). NOE : Battery voltage for first two seconds, then volts. NOE : Varies with temperature. NOE : Varies with manifold vacuum. NOE 4: Varies with throttle movement. NOE 5: ess than.5 volt (5 mv) WIRING DIAGRAMS - 4D-

24 ECM Connector and EFI Symptoms Chart Pin J- Knock Sensor Signal J- EC Signal J- Not J 4 Not J-5 Master Slave J-6 Not J-7 Diagnostic est J-8 Not J-9 Map Signal J- P Signal J- Ignition Fused J- Not J- P and IA Ground J-4 ECM Ground J-5 P 5V Reference Wire Color Component Connector 485 Knock Sensor 4 YE EC Sensor Normal Voltage Ignition ON Engine Running Pin Circuit Func- (CK) tion Number (#) Diagnostic rouble Codes DC(s) Possible Symptoms 9.5V 9.5V 4 Poor Fuel Economy, Poor Performance Detonation.95V (NOE ).95V (NOE ) 4 Poor Performance, Exhaust Odor, Rough Idle, RPM Reduction 96 YE In ine Boat Harness B+ B+ None ack Of Data From Other Engine (Dual Engine Only) 45 WH/ Data ink Connector B+ B+ None Incorrect Idle, Poor Performance 4 GRN DK BU 49 PNK/ MAP Sensor P Sensor 4.9V.46V (NOE ).6V (NOE 4).6V (NOE 4) Poor Performance, Surge, Poor Fuel Economy, Exhaust Odor Poor Performance And Acceleration, Incorrect Idle Splice B+ B+ None No Start 8 P and IA Sensor 45 / WH Engine Block 46 P,MAP Sensors, High Idle, Rough Idle, Poor Performance Exhaust Odor None No Charge 5V 5V, ack Of Power, Idle High J-6 Battery 44 ORN Splice B+ B+ None No Start See Page 4D- For NOES 4D- - WIRING DIAGRAMS

25 ECM Connector and EFI Symptoms Chart Pin J-7 Not J-8 Serial Data J-9 Not J- Not J- Not J- Not J- Not J-4 IA Sensor J-5 Not J-6 Not J-7 Not J-7 Not J-8 Not J-9 MAP Ground J- ECM Ground J- MAP 5V Reference Wire Color Component Connector Normal Voltage Ignition ON Engine Running Pin Circuit Func- (CK) tion Number (#) Diagnostic rouble Codes DC(s) Possible Symptoms 46 ORN/ Data ink Connector 5V 5V None No Serial Data 47 AN IA Sensor 5V (NOE ) Poor Fuel Economy, Exhaust Odor 84 MAP Sensor 45 / WH Engine Block 46E MAP Sensor ack Of Performance,Exhaust Odor, Stall None No Change 5V 5V ack Of Power, Surge, Rough Idle, Exhaust Odor J- Battery 44 ORN Splice B+ B+ None No Start See page 4B- for NOES WIRING DIAGRAMS - 4D-

26 ECM Connector and EFI Symptoms Chart Pin J- Not J- Not J- Not J-4 Not J-5 Injector Driver J-6 Ignition Control Ref. ow J-7 Not J-8 Ignition Control Ref. High J-9 Fuel Pump Relay Driver J- Not J- Not J- Not J- IAC A ow J-4 IAC B ow J-5 Fuel Injector Ground J-6 Not Wire Color Component Connector Normal Voltage Ignition ON Engine Running Pin Circuit Func- (CK) tion Number (#) Diagnostic rouble Codes DC(s) Possible Symptoms 468 GRN 46 / WH Injector B+ B+ None Rough Idle, ack Of Power, Stall Ignition Control Module None No Change 4 / WH 465 DK GRN/ WH Ignition Control Module Fuel Pump Relay 5V.6V None No Restart (NOE &5) B+ None No Start DK GRN Buzzer, Igniton, ach 44 BU/ 44 GRN/ WH 45 / WH See page 4B- for NOES IAC Valve IAC Valve Engine Ground Not Usable Not Usable Not Usable Not Usable None None None Rough Unstable or Incorrect Idle Rough Unstable or Incorrect Idle No Change 4D-4 - WIRING DIAGRAMS

27 ECM Connector and EFI Symptoms Chart Pin J-7 Not J-8 Not J-9 Not J- Fuel Injector Ground J- Injector Driver J- Not J- Ignition Control Signal J-4 Ignition Control Bypass J-5 Not J-6 Not J-7 Not J-8 Idle Air Control A High J-9 Ilde Air Control B ow J- Not J- Malfunction Indicator amp J- Not Wire Color Component Connector Normal Voltage Ignition ON Engine Running Pin Circuit Func- (CK) tion Number (#) Diagnostic rouble Codes DC(s) Possible Symptoms 45 / WH 467 DK BU Engine Ground None No Change Injector B+ B+ None Rough Idle, ack Of Power, Stalling 4 WH Ignition Control Module 44 AN/.V 4 Stall, Will Restart In Bypass Mode, ack Of Power 4.5V 4 ack Of Power, Fixed iming 44 BU/ WH 444 GRN/ WH IAC Valve IAC Valve Not Usable Not Usable Not Usable Not Usable None None Rough Unstable or Incorrect Idle Rough Unstable or Incorrect Idle 49 BRN/ WH See page 4B- for NOES Data ink Connector None amp Inoperative WIRING DIAGRAMS - 4D-5