FUEL SYSTEMS BODENSEE EMISSION FUEL SYSTEM 5 F

Transcription

1 FUEL SYSTEMS BODENSEE EMISSION FUEL SYSTEM 5 F

2 Tle of Contents Pge Identifition F-1 Replement Prts Wrning F-1 Torque Speifitions F-1 Speil Tools F-1 Cruretor Speifitions F-2 Cruretor Adjustment Speifitions F-2 Engine Speifitions F-2 Desription F-3 Speil Notes F-3 Cruretor Top Cover F-3 Seled Idle Mixture Srews F-3 Metering Assemly F-4 Preutions F-5 Mintenne F-6 Flme Arrestor F-6 Fuel Filter F-6 Positive Crnkse Ventiltion (PCV).... 5F-6 Trouleshooting F-7 Cheking Ported Vuum Swith nd Cruretor Vuum Ciruit for Corret Opertion F-7 Servie Proedures F-8 Cheking Positive Crnkse Ventiltion (PCV) Vlve F-8 Removing Sels From Idle Mixture Srews F-9 Instlling New Sels F-9 Cruretor Instlltion F-9 Ported Vuum Swith Instlltion F-10 Emissions System Connetions F-11 Propne Assisted Idle Set Proedure.... 5F-12 Test Equipment F-14 Emissions Testing F-14 5F-0 - BODENSEE EMISSION FUEL SYSTEM

3 Identifition The Bodensee Emissions version of the Weer WFB ruretor hs vuum fittings on the front side. NOTE: The 4.3LX version hs two fittings nd the 5.7L version hs three. The third fitting on the 5.7L version is for the fuel pump sight tue onnetion. Torque Speifitions Desription l. ft. l. in. N m Cruretor to Mnifold Fuel Line to Cruretor Speil Tools Merury Mrine Speil Tools Desription Prt Numer Universl Cruretor Guge Thometer Vuum Fittings - Extr Fitting for Fuel Pump Sight Tue on 5.7L Replement Prts Wrning! WARNING Eletril, ignition nd fuel system omponents on your MerCruiser re designed nd mnuftured to omply with U.S. Cost Gurd Rules nd Regultions to minimize risks of fire nd explosion. Use of replement eletril, ignition or fuel system omponents, whih do not omply with these rules nd regultions, ould result in fire or explosion hzrd nd should e voided. Other Speil Tools Desription Prt Numer Universl Cruretor Stnd TORX Srewdrivers (15,20&25) Otin Lolly Propne Bottle [14 oz. (400 grms)] Propne Enrihment Kit (Vrious Suppliers) Ported Vuum Swith (PVS) Soket Wrenh (Vrious Suppliers) Speil Tool Suppliers: (1) Kent-Moore Prt Numer (2) Snp-On Prt Numer (3) OTC Prt Numer (1) J26911 (2) YA7148 (3) 7148 (1) No PN (2) S9842A (3) 7267 NOTE: Weer ruretors will hve str shped soket in the hed of some srews. A TORX srewdriver must e used on this type of srew. The sizes used re numers 15, 20 nd BODENSEE EMISSION FUEL SYSTEM - 5F-1

4 Cruretor Speifitions Units of Mesurements In.(mm) Engine Model MCM 4.3LX Alph MCM 5.7L Alph Cr Type Weer WFB Weer WFB Merury Numer (Mnufturer Numer) Primry Jet Size Seondry Jet Size Metering Rod Numer Metering Rod Spring Color (9662) Nturl (9663) Nturl Cruretor Adjustment Speifitions Mke And Model Weer WFB Flot Level 1-9/32 (33) Flot Drop 2 In. (51) Pump Rod Hole Lotion Numer 3 from end (Hole losest to lever pivot point) Aelertor Pump 7/16 (11) (Note 1) Choke Pull Off 1/8 (3.5) Choke Coil Rod Top of Rod Even with Bottom of Lever Hole (Note 2) Note: 1. Mesured from top of Cruretor to ottom of S - Link Note: 2. Remove hoke rod from lever hole. hoke held losed nd hoke rod is pushed down with top edge of rod even with ottom edge of hole. Engine Speifitions Model 4.3LX Alph 5.7L Alph Thermostt 160 F (71 C) Ignition Timing Idle Speed in Neutrl Propne Idle Speed (See Proedure) 10 BTDC 775 RPM 850 RPM 5F-2 - BODENSEE EMISSION FUEL SYSTEM

5 Desription The Bodensee Emissions system is designed to lower exhust emissions to meet regultions on the Bodensee. It onsists of the following items: Positive Crnkse Ventiltion (PCV) iruit, Ported Vuum Swith (PVS) iruit, higher temperture thermostt [160 F (71 C)], nd speilly designed Weer WFB ruretor. Weer WFB ruretor is unique in design, s the min ody nd flnge re st s one piee unit. This, long with the owl over, mke up the two piee onstrution whih is mde of light, durle luminum to dissipte het. There re two seprte flot iruits. Eh flot iruit supplies fuel to primry low speed iruit nd primry nd seondry high speed iruit. The owls re vented to the inside of the ir horn. A onneting vent pssge effets lne of the ir pressure etween the two owls. The flot needle vlves re instlled t n ngle to provide the est possile seting tion on the needles. This provides etter needle response to flot movement, lso. The PVS iruit is used in onjuntion with the idle iruit. When the engine is old, the PVS iruit is losed. This shuts off metered ir-leed to the idle iruit, to mintin rih idle iruit for wrm-up. One the engine wrms up [ pproximtely 128 F (54 C)], the PVS opens, llowing metered mount of ir to e mixed into the idle iruit. This lens the idle iruit to the proper operting ir-fuel rtio. The high speed iruits use stged step-up rods in the min metering jets to ontrol the mount of fuel dmitted to the nozzles. The position of the step-up rod is ontrolled y mnifold vuum pplied to the vuum piston. A primry ir leed loted in the venturi luster prevents rih ondition or og s the high speed iruit is retivted fter deelertion. Smll L shped metl ts, lled distriution t(s), re tthed to some venturi lusters nd protrude into the ir strem t the proper lotion to id distriution of fuel on seleted pplitions. The PCV iruit ventiltes rnkse vpors (unurned gses) k into the intke mnifold to e urned gin. Speil Notes IMPORTANT: Disssemly nd repir of the Bodensee Emissions ruretor is silly the sme s the other Weer WFB ruretors. There re some internl nd externl differenes tht re noted following: Cruretor Top Cover The ruretor top over (ir-horn) hs vuum fittings for onnetion to the Ported Vuum Swith (PVS). The 5.7L version lso hs fitting for the fuel pump sight tue. - Vuum Fittings - Fitting for Fuel Pump Sight Tue (5.7L ONLY) Seled Idle Mixture Srews The idle mixture srews hve sels tht prevent tmpering with the idle mixture fter the mixture hs een properly djusted Srew Sels BODENSEE EMISSION FUEL SYSTEM - 5F-3

6 Metering Assemly The metering rod ssemlies re different in the following wys: Emissions METERING JETS The metering jets in this ruretor re tller thn the jets in stndrd ruretor. Emissions Stndrd d e Jet for 3-Step Metering Rod - Jet for 2-Step Metering Rod METERING ROD HAS THREE STEPS -VS- TWO Emissions Stndrd Stndrd d e PISTON SHAPE IS DIFFERENT AND HAS A SECOND SPRING Emissions - Piston - Metering Rod - Spring d - Jet e - Piston Cover Stndrd F-4 - BODENSEE EMISSION FUEL SYSTEM

7 PISTON ASSEMBLY COVER IS HIGHER Preutions! WARNING Alwys disonnet ttery les from ttery BEFORE working on fuel system to prevent fire or explosion.! WARNING Emissions Stndrd PISTON BORE HAS A STEP ON EMISSIONS MODEL Be reful when lening flme rrestor nd rnkse ventiltion hose: gsoline is extremely flmmle nd highly explosive under ertin onditions. Be sure tht ignition key is OFF. DO NOT smoke or llow soures of sprk or open flme in re when lening flme rrestor nd rnkse ventiltion hose.! WARNING Be reful when hnging fuel system omponents: gsoline is extremely flmmle nd highly explosive under ertin onditions. Be sure tht ignition key is OFF. DO NOT smoke or llow soures of sprk or open flme in re while hnging fuel filter. Wipe up ny spilled fuel immeditely.! WARNING Mke sure no fuel leks exist, efore losing engine hth.! CAUTION DO NOT operte engine without ooling wter eing supplied to wter pikup holes in ger housing or wter pikup inlet, or wter pump impeller will e dmged nd susequent overheting dmge to engine my result BODENSEE EMISSION FUEL SYSTEM - 5F-5

8 Mintenne Flme Arrestor Mintenne for the flme rrestor is the sme s stndrd engine (See the Weer WFB ruretor setion of the pproprite MerCruiser Servie Mnul). The only differene in the flme rrestor on n engine with the Bodensee Emissions system is in the vent hose rket. This rket hs fitting on one side only. Fuel Filter Mintenne for fuel inlet filters is the sme s stndrd engine (See the Weer WFB ruretor setion of the pproprite MerCruiser Servie Mnul). Positive Crnkse Ventiltion (PCV) The Positive Crnkse Ventiltion (PCV) vlve should e repled one yer. d PCV Vlve - Hose Stud - Vent Hose Brket - Vent Hose to Strord Vlve Cover d - NO VENT HOSE ON THIS SIDE 5F-6 - BODENSEE EMISSION FUEL SYSTEM

9 Trouleshooting NOTE: Review the Desription setion of this mnul for n understnding of system opertion, efore trouleshooting the ruretor. Do not ssume tht prolem exists inside the ruretor without first eliminting other engine system omponents s potentil prolem res. Be sure to hek the following items: Engine operting temperture (Proper Thermostt - See Engine Speifition Chrt ). Corret ignition timing (See Engine Speifition Chrt ). Cylinder ompression. Ported Vuum Swith (PVS) funtioning properly. Use the following proedure to hek for fulty Ported Vuum Swith (PVS): Cheking Ported Vuum Swith nd Cruretor Vuum Ciruit for Corret Opertion NOTE: The engine must e old efore performing the first 4 steps. 1. Strt engine. Disonnet the hose from the ruretor t the lotion shown. 2. Plug the hose with your finger. You should not feel vuum on the hose t this time Allow engine to run nd wrm up to norml operting temperture. Disonnet the hose gin nd hek for vuum. If PVS is funtioning properly, there should e vuum present t this time. If vuum is not present, hek to ensure tht hoses re properly onneted nd re not rked or plugged. Then, proeed to hek the ruretor vuum iruit. 4. Reonnet rer hose to ruretor. NOTE: The engine must e wrm efore performing the next step. 5. Strt engine nd llow it to reh norml operting temperture. 6. Disonnet the two hoses on the front of ruretor BODENSEE EMISSION FUEL SYSTEM - 5F-7

10 IMPORTANT: Ensure tht engine is running t 775 RPM or elow. This ensures tht the ruretor is not running on the Off-Idle iruit. 7. Connet thometer to the engine. 8. Plug the vuum ports on the front of the ruretor. Be sure to only plug one port t time. When vuum port is overed, the engine RPM should inrese. Repet test on the other port. If vuum is not present, vuum port my e plugged. Clen vuum ports nd repet the entire test. Servie Proedures Cheking Positive Crnkse Ventiltion (PCV) Vlve 1. Strt engine nd llow it to reh norml operting temperture. 2. Remove PCV vlve from vlve over. Plug the opening with your finger. A vuum should e felt. 3. Stop the engine. 4. Shke the vlve to ensure tht the internl omponents re free to move When test is omplete nd PVS is determined to e funtioning properly, reonnet ll hoses in vuum iruit. 5F-8 - BODENSEE EMISSION FUEL SYSTEM

11 Removing Sels From Idle Mixture Srews! WARNING 2. Align the opening in the plug with the t on the up nd push down until it snps in ple. Avoid fire or explosion. Using utting wheel to ut the sels will use sprks, whih will ignite ny fuel tht is present. Ensure tht there is no fuel present nd tht ruretor is removed from engine prior to utting the sels from the ruretor idle mixture srews. 1. Remove ruretor from the engine. 2. Drin ll fuel from the ruretor. 3. Using utting wheel, mke ut on oth sides of the sel sing. Using suitle devie, pry the plug from the inside of the sel. One the plug is removed, the idle mixture srew n e removed nd the sel sing n e removed. - Opening in Plug - T on Cup Cruretor Instlltion NOTE: The dpter plte is not used on the 4.3LX Alph model. 1. If dpter plte ws removed, ple the gsket tht mthes the outside edge of the intke mnifold surfe etween the intke mnifold nd the plte. Instll ruretor dpter plte. Seure with the llen-hed srews. Torque to 132 l.in. (15 N m). Apply Lotite 271 to threds nd instll studs Instlling New Sels 1. Instll new sel up, spring nd idle mixture srew. IMPORTANT: Do not instll the sel plug until the Propne Assisted Idle Mixture Adjustment proedure hs een ompleted Adpter Plte (Not on 4.3LX Alph Model) - Srews - Studs BODENSEE EMISSION FUEL SYSTEM - 5F-9

12 2. Instll new ruretor s follows:. Ple new gsket on dpter plte.. Instll ruretor nd throttle rket nd seure with new tthing hrdwre. Torque fsteners to 132 l.in. (15 N m).. Connet fuel line. To prevent over-tightening, hold fuel inlet nut with suitle wrenh nd tighten fuel line onnetor seurely. d Ported Vuum Swith Instlltion! CAUTION Be reful not to rek off fittings when instlling the ported vuum swith (PVS) in the following step. NOTE: A speil tool is ville to instll the PVS. Refer to the Tool Chrt t the eginning of this mnul. 1. If removed, instll ported vuum swith (PVS) into reduer ushing. Apply Lotite Pipe Selnt with Teflon to threds efore instlling. Tighten it seurely nd position the fittings towrd k of engine s shown Reduer Bushing - Ported Vuum Swith (PVS) Throttle Brket - Atthing Hrdwre - Fuel Line d - Fuel Inlet Nut 5F-10 - BODENSEE EMISSION FUEL SYSTEM

13 Emissions System Connetions 1. Instll the positive rnkse ventiltion (PCV) vlve in the port vlve over. 2. Connet hose to PCV vlve. Connet opposite end of hose to fitting on front of ruretor. 3. Connet hoses to ported vuum swith (PVS) s shown. d d e Ported Vuum Swith - Hoses (Swith to Y-Fitting) - Hoses (To Front Side of Cruretor) d - Hose (Y-Fitting to Bk Side of Cruretor) e - Sight Tue from Mehnil Fuel Pump (Cler Hose) NOTE: The fuel pump sight tue hose (e) shown ove is not present on the 4.3LX version. The fitting does not exist on tht ruretor. - PCV Vlve - Hose - Cruretor Fitting (Connet Hose Here) BODENSEE EMISSION FUEL SYSTEM - 5F-11

14 IMPORTANT: The hose tht runs from the T-Fitting to the k side of the ruretor must e routed eneth the throttle linkge s shown in the following illustrtion. Use re to ensure tht the hose does not ru ginst linkge Propne Assisted Idle Set Proedure! WARNING Avoid fire or explosion. Oserve the following preutions when performing this proedure. Do not operte the engine without the flme rrestor instlled, ove the speeds listed in this proedure. Propne is extremely flmmle nd explosive. Ensure tht the following test is performed in well ventilted re with the engine hth open. Ensure tht there is no sprk or open flme in the test re. Do not strt the flow of propne until the hose hs een pled into the ruretor nd the engine hs een strted. Keep fire extinguisher ville when performing this test. NOTE: This test must e performed ny time the ruretor hs een disssemled nd internl omponents hve een distured or the idle mixture srews hve een tmpered with. The test should lso e performed if other omponent prts of the emissions system hve een ltered, repired, or repled. IMPORTANT: Ensure tht the PVS is funtioning properly efore performing this proedure. 1. As strting point, set oth idle mixture srews t 1 turn out from the fully seted position. 2. Strt engine nd llow it to wrm up to norml operting temperture. If engine hs een run ove idle speed, llow engine to idle for 3 to 5 minutes to stilize the engine. 3. Remove flme rrestor. 4. Insert speil Y -Adpter hoses into ruretor s shown. Ple the hoses ehind the hoke plte to help hold them in ple. -T-Fitting - Hose T-Fitting to Bk of Cruretor) F-12 - BODENSEE EMISSION FUEL SYSTEM

15 5. Connet the hose from the propne ottle vlve to the Y -Fitting. 6. With engine idling t norml operting temperture, press the propne flow utton on the vlve. Slowly egin opening the propne metering vlve until mximum engine RPM is rehed. When too muh propne is dded, engine RPM will derese. Fine tune the metering vlve to otin the highest RPM. 8. Relese the propne flow vlve nd llow engine speed to stilize. Slowly djust the mixture srews y equl mounts, pusing etween djustments to llow engine speed to stilize, to hieve 775 RPM Propne Flow Vlve - Propne Metering Vlve 7. With propne still flowing, djust the idle speed srew (not the mixture srews) to otin 850 RPM. Agin, fine tune the propne metering vlve to otin the highest engine RPM. If there hs een hnge in the mximum RPM, redjust the idle speed srew to 850 RPM. 9. Press the propne flow vlve. Engine RPM should inrese to 850 RPM. If it does not, repet steps 5 thru If fter performing the ove proedure severl times, the orret results n still not e otined, hek the following: PVS not working properly. Inorret flot level. Vuum leks BODENSEE EMISSION FUEL SYSTEM - 5F-13

16 11. One the idle speed nd mixture djustment is orret, instll the sel plugs over mixture srews. Ensure the opening in plug snps into the t in the up Emissions Testing NOTE: This test will e performed y n uthorized geny for the re tht the ot will e operted. This geny will e equipped with the pproprite test equipment nd dpters for this engine. The only item tht must e supplied y the ot owner/opertor re the exhust test proes. These test proes should e rried ord the vessel t ll times. The following steps will explin how these proes re to e instlled. - Srew Sels - T in Cup - Opening in Plug 12. Reinstll the flme rrestor Exhust Test Proes (2) - Exhust Elow Adpter Fittings (2) 1. Remove plugs from oth exhust elows Test Equipment The following equipment is needed to perform n emissions test on this engine: Test Proes (Supplied in Kit). Test Proe Colletor (Testing Ageny). Exhust System Anlyzer (Testing Ageny) Plugs (Port nd Strord Elows) Exhust Proe Colletor - To Exhust Anlyzer 5F-14 - BODENSEE EMISSION FUEL SYSTEM

17 2. Instll exhust elow dpter fittings into elows. Apply Lotite Pipe Selnt with Teflon to threds tht go into elow. Tighten seurely. 3. Insert exhust test proes into fittings nd tighten seurely. NOTE: Be ertin to ple test proes nd dpter fittings in suitle storge ord the ot for use in the future. NOTICE TO OWNER/OPERATOR Your engine is equipped with speil design fetures nd speil tuning to minimize the emission output from the engine. You should follow: Reommended mintenne shedules prtiulrly s to the ignition system. Proper engine tuning proedures to ensure these fetures remin in good operting order. Proper steps to mintin the engine within speifition The instrutions in the Emissions Kit provide the neessry informtion to properly onvert the engine to meet the pplile Bodensee Regultions. There is nother item within the regultion tht is eyond the ontrol of Merury Mrine. This item is relted to the fuel filling system on the ot. The requirements for the fuel filler nek re s follows: Must e designed so tht it is impossile to use fuel nozzle with n outside dimeter of more thn 23.6 mm. The filler nek shll e durle nd designed so tht modifitions re not possile. A durle, legile plte shll e mounted on the ot ner the fuel filler nek. This plte shll red: UNLEADED GASOLINE ONLY. - Fittings - Exhust Test Proes 4. When exhust emissions test is omplete, remove test proes nd dpter fittings nd reinstll the plugs. Apply Perfet Sel to threds efore instlling. Tighten them seurely. Any questions out the fuel filler nek requirement nd vilility of the required omponents should e direted to the ot mnufturer BODENSEE EMISSION FUEL SYSTEM - 5F-15