Spark Plug Fouling 3.0 Liter OptiMax

Transcription

1 WARRANTY INFORMATION PARTS INFORMATION SERVICE INFORMATION Bulletin No Circulte to: Sles Mnger Accounting Service Mnger Technicin Prts Mnger Sprk Plug Fouling 3.0 Liter OptiMx Models Affected MERCURY/MARINER 2001/2002 Model 200/ Liter OptiMx 0T Thru 0T Sitution Some 2001 model yer engines my continue to experience sprk plug fouling fter the product upgrdes outlined in Service Bulletins nd hve been performed. In ddition, some 2002 model yer engines my lso experience sprk plug fouling. If sprk plug fouling occurs, check the following systems nd perform ny necessry repirs or upgrdes. If these engine checks, repirs nd upgrdes do not resolve the plug fouling condition, contct: US Delers The OPTIMAX ASSISTANCE TEAM t , enter request for technicl ssistnce in the service section of MercNET or complete nd send QuickFx form ( ) to for further ssistnce. CANADIAN Delers Technicl support t or enter request for technicl ssistnce in the service section of MercNET or complete nd send Q.sos fx form ( ) to INTERNATIONAL Delers Follow instructions issued by Mrine Power Interntionl Office or by your distributor JUNE 2002 Printed in U.S.A , Mercury Mrine Pge 1 of 6

2 Inspection/Correction SENSOR AND ENGINE INFORMATON: The idel tool for checking engine temperture, sensor redings, nd engine dt is the Digitl Dignostic Tester (DDT). When looking t engine sensor redings nd engine dt, not only should you look for fult codes, you should lso look for redings tht don t mke good sense. Exmples: A MAP sensor reding with the ignition key in the ON position prior to engine strt up normlly reds higher number thn when running t idle speed. MAP sensor redings tht do not chnge with throttle chnges or MAP sensor redings tht keep chnging when there is no chnge to throttle opening or engine speed re ll indictions of problem. An ir temperture sensor reding of 4 C [40 F] on dy with outside tempertures of 32 C [90 F] just does not mke sense. These re only two exmples of incorrect sensor redings tht would not store fult code becuse the sensor is still within its norml working rnge. Incorrect sensor redings cn contribute to sprk plug fouling. Sensors furnishing incorrect redings should be replced. ENGINE TEMPERATURE: A new 54 C [130 F] thermostt nd new thermostt cover hve been developed tht will help mintin higher engine temperture nd reduce the chnce of debris holding the thermostt open. A thermostt held open by debris would reduce engine temperture cusing sprk plug fouling. If n engine is in for sprk plug fouling condition, instll thermostt kit P/N A1. This kit includes ll of the covers, thermostts nd gskets to upgrde one engine. NOTE: Sometimes low engine temperture t idle cn be cused by wter leking pst the relief/poppet vlve. Check the relief/poppet vlve if the new thermostts do not correct low engine temperture condition. Norml engine temperture using the new 54 C [130 F] thermostts is 46 C - 60 C [115 F F] Sel is bonded to the new thermostt to prevent lekge round sel b-new covers with nrrow thermostt lnds, llow MOST debris to pss through the system b Pge 2 of 6 JUNE

3 SPARK PLUG nd SPARK PLUG WIRES: Dmged or loose sprk plug wires my cuse plug fouling. Most wire dmge is the result of rough hndling nd the use of incorrect tools to remove nd instll wires. For more informtion on this see service bulletin Check tht ll plug wires re totlly engged onto the coil towers nd the sprk plugs. Check the sprk plug wire boots for dmge. NOTE: Slightly stretching the boot my show cut or hole tht otherwise my not be seen. New sprk plugs re normlly gpped correctly, but should be checked prior to instlltion (plug gp 1.1 mm [.043 in.]). NOTE: To prevent sprk plug cross threding, use piece of hose pushed over the plug. (Gry fuel hose with 8 mm [.315 in.] I.D. works well.) This will llow you to thred the plug into the sprk plug hole by hnd while voiding cross-threding. Torque plugs to 27 Nm [20 lbs. ft.]. -Rubber hose slid over sprk plug for instlltion of plug JUNE 2002 Pge 3 of 6

4 IDLE EXHAUST BOOT: Check for exhust or wter leking from the exhust boot where it connects to the dpter plte. When the engine is running t idle speed, put slight side pressure on the boot ner the dpter plte. If you see wter or exhust leking/spitting out between the boot nd dpter plte the boot is leking nd needs to be reseled. A leking exhust boot will cuse exhust gses to be ingested into the engine when running with the cowl on, contributing to sprk plug fouling. Remove the boot from the dpter plte. Clen the re of the boot nd dpter plte where the two join together. Both surfces must be clen nd dry (no oily residue). Glue the boot bck in using Loctite Ultr Copper RTV, vilble loclly. b c Idle exhust relief boot b-apply selnt completely round this re of exhust boot c -Idle exhust boot opening in dpter plte, clen prior to instlltion Pge 4 of 6 JUNE

5 DIRECT INJECTORS: Check the resistnce (ohms vlue) of the direct injector coil winding nd determine if there is short-circuit between the winding nd engine ground. Incorrect ohms reding or shorted winding will cuse n incorrect fuel/ir spry pttern, contributing to sprk plug fouling. The correct reding should be between 1.0 nd 1.6 ohms. If the reding is inccurte replce the injector. b Direct injector ohm test between the two connector pins ( ohms) b-direct injector short to ground ohm test (no continuity), check between either connector pin nd the metl portion of the injector NOTE: Mking resistnce checks on direct injector while still instlled in the engine cn be difficult. An esy nd fst wy to mke resistnce (ohms vlue) checks on direct injectors is to use service hrness end P/N A2, shown below. This hrness is normlly used s service replcement prt for the direct injector connector if it becomes dmged, but lso works well to mke the required resistnce nd ground test while the injector is in plce between the cylinder hed nd fuel ril. Disconnect the hrness connector going to the specific direct injector tht you re testing, nd connect the service hrness to tht injector. Next mke the resistnce (ohms vlue) check ( ohms) between the two wires nd the ground check between either wire nd good engine ground JUNE 2002 Pge 5 of 6

6 PROPPING: Bots tht re over propped (using propellers with too high pitch for the ppliction) my experience sprk plug fouling. Most of us think of over propping to be Wide Open Throttle (WOT) issue. But n over propped engine will lso cuse hevier lods t lower speeds. These hevier lods require more fuel, contributing to sprk plug fouling. Verify tht the engine is propped to the top end of its recommended RPM rnge under the norml running conditions/bot lod. Wrrnty Mercury Mrine will credit the deler for the cost of prts nd lbor for one yer from the issunce of this bulletin. Plese note the month nd yer locted t the lower left corner of the front pge of this document. Complete wrrnty clim listing: Outbord seril number Prts s required Flt Rte Code: NJC nd totl lbor llownce Prt Code: 320 Filure Code: 00 Lbor Time Chrt Description of repir or test Lbor time llowed DDT dignostic time (sensors & engine temperture) 0.5 Thermostt nd thermostt cover replcement 0.3 Sprk plugs/wire inspection nd replcement 0.6 Idle exhust boot inspection 0.1 Idle exhust boot resel 0.5 Direct injector resistnce (ohms) test 0.1 Direct injector replcement (one) 0.6 US nd Cnd Tg nd hold prts for 60 dys fter the wrrnty credit is received. Interntionl Hold prts for inspection/disposl by Mrine Power Interntionl technicl representtive. Pge 6 of 6 JUNE