Electrical System. Table of Contents. Section 4C - MPI Ignition System. MPI Ignition System

Transcription

1 Eletril System MPI Ignition System Tle of Contents Setion 4C - MPI Ignition System Preutions...4C-2 MerCruiser Color Wiring Digrms...4C-4 MPI Ignition Speifitions...4C-2 Torque Speifitions...4C-3 Finding Top Ded Center (TDC)...4C-3 Sprk Plugs...4C-5 Removl...4C-5 Inspetion...4C-5 Instlltion...4C-5 Sprk Plug Wires...4C-6 Inspetion...4C-6 Instlltion...4C-6 Ignition Coil...4C-7 Removl...4C-7 Instlltion...4C-8 MPI Distriutor...4C-8 MPI Distriutor Exploded View...4C-8 Distriutor Cp Removl...4C-9 MPI Distriutor Removl...4C-9 MPI Distriutor Disssemly...4C-9 Distriutor Assemly...4C-0 MPI Distriutor Instlltion...4C-0 Sorpion Distriutor...4C-2 Sorpion Distriutor Exploded View...4C-2 Sorpion Distriutor Removl...4C-2 Sorpion Distriutor Disssemly...4C-3 Sorpion Distriutor Assemly...4C-3 Sorpion Distriutor Instlltion...4C-4 4 C AUGUST 2009 Pge 4C-

2 Preutions! WARNING Avoid fire or explosion hzrd. Eletril, ignition, nd fuel system omponents on Merury Mrine produts omply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replement eletril or fuel system omponents tht do not omply with these stndrds. When serviing the eletril nd fuel systems, properly instll nd tighten ll omponents.! WARNING Neglet or improper mintenne, repirs, or inspetions of the power pkge n result in produt dmge or serious injury or deth. Perform ll proedures s desried in this mnul. If you re not fmilir with proper mintenne or servie proedures, onsign the work to n uthorized Merury Mrine deler.! WARNING Performing servie or mintenne without first disonneting the ttery n use produt dmge, personl injury, or deth due to fire, explosion, eletril shok, or unexpeted engine strting. Alwys disonnet the ttery les from the ttery efore mintining, serviing, instlling, or removing engine or drive omponents.! WARNING Explosive fumes ontined in the engine omprtment n use serious injury or deth from fire or explosion. Before strting the engine, operte the ilge lower or vent the engine omprtment for t lest five minutes.! WARNING Fuel is flmmle nd explosive. Ensure tht the key swith is off nd the lnyrd is positioned so tht the engine nnot strt. Do not smoke or llow soures of sprk or open flme in the re while serviing. Keep the work re well ventilted nd void prolonged exposure to vpors. Alwys hek for leks efore ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. IMPORTANT: To void dmging the eletril system, follow these preutions: Do not tp essories into the engine hrness. Do not punture wires for testing (proing). Do not reverse the ttery leds. Do not splie wires into the hrness. Do not ttempt dignostis without the proper, pproved servie tools. MPI Ignition Speifitions! WARNING Avoid fire or explosion hzrd. Eletril, ignition, nd fuel system omponents on Merury Mrine produts omply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replement eletril or fuel system omponents tht do not omply with these stndrds. When serviing the eletril nd fuel systems, properly instll nd tighten ll omponents. Distriutor Desription Distriutor (prt numer) Speifition A02 Coil Pge 4C AUGUST 2009

3 Desription Speifition Coil (pr numer T Primry resistne 0.60 to 0.80 ohms Seondry resistne 9,400 to,700 ohms Sprk Plugs Prodution Yers Prior to April Prior to April Engine MPI 5.0 liter (305 CID), 5.7 liter (350 CID), nd 6.2 liter (377 CID) OEM Sprk Plug Merury Prt Numer AC Delo: Blk Sorpion nd MX 6.2 AC Delo: Gp After to April MPI 5.0 liter (305 CID), 5.7 liter (350 CID), nd 6.2 liter (377 CID) AC Delo: After to April Blk Sorpion nd MX 6.2 AC Delo: Firing Order nd Ignition Timing Desription Speifition Firing order Ignition timing Torque Speifitions NOTE: Seurely tighten ll fsteners not listed elow. Desription Nm l in. l ft Sprk plugs (new ylinder hed) Sprk plugs (used ylinder hed) 4 32 Distriutor lmping srew Knok sensor 9 4 Finding Top Ded Center (TDC) IMPORTANT: Do not insert nything into sprk plug hole while turning the engine over. Position ylinder numer one t TDC y either of the following methods:. Remove the ylinder numer sprk plug. 2. Atth suitle soket nd drive to the rnkshft pulley nut. 3. Ple finger over the plug hole nd turn the engine over in its norml rottion until ompression is felt in the numer ylinder. ECM AUGUST 2009 Pge 4C-3

4 4. Continue turning the engine over y hnd until the lok mounted timing pointer ligns with the 0 timing mrk on the rnkshft pulley. 6 0 V V Crureted engine models "0" mrk on rnkshft lner MPI engine models "0" mrk on rnkshft lner. Atth suitle soket nd drive to the rnkshft pulley nut. 2. Remove the left (when oserved from the rer of the engine) roker rm over nd turn the engine in its norml rottion until the numer ylinder intke vlve is fully losed. 3. Continue turning the engine over y hnd until the lok mounted timing pointer ligns with the 0 timing mrk on the rnkshft pulley. Lurints, Selnts, Adhesives Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene High tension wire oil tower Outside rim of the oil high tension led tower SAE Engine Oil 30W Distriutor shft Otin Lolly MerCruiser Color Wiring Digrms Lrge sle, oversized olor wiring digrms re ville in the MerCruiser Digrm Binder. The initil distriution of the MerCruiser Digrm Binder ws delivered to MerCruiser uthorized repir filities in June nd July of As new digrms re developed they will e distriuted long with revised, omprehensive index for ddition to n existing inder. The MerCruiser Digrm Binder fetures: An index tht identifies the digrms y hrness numer, y engine group nd drive, nd y engine size nd type The digrms re printed on n extremely durle, oted syntheti pper nd n e wiped len of grese nd oil fter use. The lrger digrms re esier to red. The digrms will ome in two sizes, depending on the omplexity of the relted hrness. Removle pges re esier to referene nd llow the tehniin to tke only the required digrm to repir site insted of omplete servie mnul. Dry erse mrkers n e used diretly on the digrms for tring iruits or for trining. They wipe len fter use. Pge 4C AUGUST 2009

5 Hrness numer hedings mke the drwings esy to find. The ompnying MerCruiser Digrm Binder Index speeds lookup when the hrness numer is not known. For informtion out ordering dditionl opies of the MerCruiser Digrm Binder or inder updtes ontt: MerCruiser Authorized Delers, Repir Centers, or OEMs n order servie literture on MerNET. Consumers n order servie literture through the Merury Dok Store ( ontting Merury MerCruiser pulitions t or y ontting their lol MerCruiser Authorized Deler or Repir Center. Sprk Plugs Removl. Disonnet the sprk plug wires (high tension leds) from the sprk plugs. NOTE: Use re when removing the sprk plug wires from the sprk plugs. Twist the oot /2 turn efore removing. Firmly grsp nd pull on the oot not the wire. 2. Remove the sprk plugs. Inspetion NOTE: A thin wlled sprk plug soket my e required.. Inspet eh sprk plug for the mnufturer nd sprk plug numer. All plugs must e from the sme mnufturer nd hve the sme sprk plug numer. Prodution Yers Prior to April Prior to April Engine MPI 5.0 liter (305 CID), 5.7 liter (350 CID), nd 6.2 liter (377 CID) OEM Sprk Plug Merury Prt Numer AC Delo: Blk Sorpion nd MX 6.2 AC Delo: Gp After to April After to April MPI 5.0 liter (305 CID), 5.7 liter (350 CID), nd 6.2 liter (377 CID) AC Delo: Blk Sorpion nd MX 6.2 AC Delo: Inspet eh plug individully for worn eletrodes nd for glzed, roken, or listered porelin. Chek the joint etween the insultor nd the shell for rks. Reple s neessry. Instlltion. Clen the ylinder hed sprk plug set Typil sprk plug AUGUST 2009 Pge 4C-5

6 2. Adjust the sprk plug gp with the ppropritely sized round tipped feeler guge. Sprk plug gp 2982 Prodution Yers Prior to April Prior to April Engine MPI 5.0 liter (305 CID), 5.7 liter (350 CID), nd 6.2 liter (377 CID) OEM Sprk Plug Merury Prt Numer AC Delo: Blk Sorpion nd MX 6.2 AC Delo: Gp After to April MPI 5.0 liter (305 CID), 5.7 liter (350 CID), nd 6.2 liter (377 CID) AC Delo: After to April Blk Sorpion nd MX 6.2 AC Delo: IMPORTANT: In the sene of torque wrenh or if ess to the plugs prevents torquing, hnd tighten the sprk plug until it sets in the ylinder hed nd then seurely tightened with the pproprite rthet nd soket. 3. Instll the sprk plugs nd torque. Desription Nm l in. l ft Sprk plugs (new ylinder hed) Sprk plugs (used ylinder hed) Instll the sprk plug wires in the proper order. Sprk Plug Wires Inspetion NOTE: Use re when removing the sprk plug wires nd the oots from the sprk plugs. Twist the oot /2 turn efore removing. Firmly grsp nd pull on the oot to remove the wire.. Visully inspet the sprk plug wires nd the oil wire for dmge. 2. Visully inspet the sprk plug oots for dmge. 3. Chek the sprk plug wires nd the oil wire for ontinuity using multi meter. 4. Reple ny dmged wires. Instlltion IMPORTANT: Only use sprk plug wires reommended for mrine pplitions. NOTE: Reple one sprk plug wire t time to redue the risk of routing error.. Disonnet eh individul sprk plug wire s it is to e repled. 2. Instll the replement sprk plug wires in the proper order. Oserve the following:. Reinstll the wires in the sprk plug wire retiners. Pge 4C AUGUST 2009

7 . Atth the plug wires to the pproprite sprk plug nd terminl on the distriutor p. Eh end should fit seurely Distriutor - Left ylinder nk - Crnkshft pulley d - Right ylinder nk d Apply selnt to the outside of the high tension wire oil tower. Insert the oil wire (high tension led) to enter terminl on distriutor p, push the oot down over the oil tower nd wipe off exess selnt. Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene High tension wire oil tower NOTE: Ensure tht the high tension wire oot does not ome loose when pushing the wire into the terminl. Ignition Coil Removl. Disonnet wire hrness onnetors t ignition oil. MPI Ignition oil - Ignition oil - High tension led - Engine hrness onnetor 2. Remove the high tension oil led Remove the oil rket srews nd rket with the ignition oil. - Coil rket srews - Ignition oil Remove the ignition oil from the oil rket AUGUST 2009 Pge 4C-7

8 Instlltion. Instll the ignition oil nd rket to the engine rket. IMPORTANT: Apply selnt to the outside of the high tension wire oil tower. Do not llow selnt inside the oil tower. 2. Apply thin ed of selnt round the outside rim of the oil high tension led tower. Ensure tht selnt is not pplied inside the oil high tension led tower. - Ignition oil - High tension led tower - Wiring hrness onnetor 2936 Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene Outside rim of the oil high tension led tower Connet high tension oil led. 4. Connet the wire hrness onnetor. MPI Distriutor MPI Distriutor Exploded View Distriutor p 2 - Srew 3 - Rotor 4 - Shft 5 - Eletroni module 6 - Housing 7 - Gsket 8 - Tng wsher 9 - Wsher 0 - Ger - Pin Pge 4C AUGUST 2009

9 Distriutor Cp Removl. Set ylinder No. to TDC. 2. Lel then remove ll sprk plug wires from the distriutor p. 3. Loosen the distriutor p retining srews. 4. Lift p wy from distriutor. MPI distriutor p - Distriutor p - Srews (2) 5. Inspet the distriutor p for rks or ron trking. Reple the distriutor p if it shows ny sign of dmge, orrosion, or if the inner eletril ontts show signs of erosive wer. 6. Inspet the rotor for rks or ron uildup. Reple the rotor if it shows ny sign of dmge, orrosion, or if the inner eletril ontt show signs of erosive wer. MPI Distriutor Removl. Verify tht ylinder No. is t TDC. 2. Lel nd remove the sprk plug wires. 3. Remove the 2 srews fstening the distriutor p to the distriutor. 4. Remove the distriutor p nd set it side. 5. Mke indexing referene mrks on the distriutor housing nd engine lok. 6. Remove olt nd hold down lmp Distriutor - Hold down olt - Hold down rket 7. Remove the distriutor nd the gsket from the intke mnifold. IMPORTANT: To ese instlltion, do not turn the engine over while the distriutor is removed. MPI Distriutor Disssemly Remove the two torx srews tthing the rotor to the distriutor. 2. Remove the rotor from the distriutor shft. 3. Remove roll pin, wsher, nd drive ger from distriutor shft. 4. Remove the distriutor shft from the housing. 5. Chek for side ply etween shft nd distriutor housing ushings. Desription Distriutor shft to housing side ply 6. Remove shft from housing. Speifition 0.05 mm (0.002 in.) mximum AUGUST 2009 Pge 4C-9

10 7. Chek the distriutor shft runout with dil inditor nd V loks. Desription Distriutor shft runout Speifition 0.05 mm (0.002 in.) mximum Distriutor Assemly. Lurite distriutor shft with engine oil nd instll into the housing. Tue Ref No. Desription Where Used Prt No. 80 SAE Engine Oil 30W Distriutor shft Otin Lolly 2. Instll the tng wsher, the wsher nd the drive ger onto the shft. 3. Temporrily instll the rotor on the shft. Using the srie mrks mde during distriutor removl, lign the drive ger, the housing, nd the rotor. 4. Instll the roll pin through the drive ger nd the distriutor shft. 5. Spin the distriutor shft to ensure tht it spins freely. 6. Align the distriutor shft keywys. Keywy lignment - Upper keywy - Lower keywy Instll the rotor onto the distriutor shft. The rotor tng must e ligned with the srie mrks mde during distriutor removl. MPI Distriutor Instlltion. Verify tht ylinder numer one is t TDC. If not follow either of the following methods to position ylinder No. t TDC: IMPORTANT: Do not insert nything into sprk plug hole while turning the engine over.. Remove the No. sprk plug. Atth suitle soket nd drive to the rnkshft pulley nut. Ple finger over the plug hole nd turn the engine over y hnd until ompression is felt in the No. ylinder. Continue turning the engine over y hnd until the lok mounted timing pointer ligns with the timing mrk on the rnkshft pulley.. Atth suitle soket nd drive to the rnkshft pulley nut. Remove the left (when oserved from the rer of the engine) roker over nd turn the engine over y hnd until the No. ylinder intke vlve is fully losed. Continue turning the engine over y hnd until the lok mounted timing pointer ligns with the timing mrk on the rnkshft pulley. 2. Position the distriutor rotor so tht it would fire ylinder No. y ligning the srie mrks mde during distriutor removl. 3. Instll new gsket on the distriutor housing. IMPORTANT: Do not use the hold down lmp nd olt to fore the distriutor into position. 4. Slide the distriutor into the lok until it stops on its own. Do not fore the distriutor. Pge 4C AUGUST 2009

11 IMPORTANT: Ensure tht the oil pump shft is properly engged. If the engine hs een tuned over fter disssemly it my e neessry to reposition the oil pump shft. Distriutor Instlltion 5. Rise the distriutor up from its initil stopping point nd rotte the rotor pproximtely /8 turn ounterlokwise. 6. Continue lowering the distriutor into the lok gently working the distriutor nd rotor so tht the oil pump shft nd mshft ger re properly engged. It my e neessry to rotte the rotor slightly until enggement is felt. 7. When properly instlled, the distriutor housing is in full ontt with the mhined relief in the intke mnifold. 8. Instll the hold down lmp over the distriutor nd torque the olt Distriutor - Bolt - Hold down lmp Desription Nm l in. l ft Distriutor hold down lmp olt Connet ll ignition ontrol wiring. 0. Instll the distriutor p. Ensure tht the rotor is still pointing t the No. ylinder plug wire terminl.. Connet the sprk plug wires. Remove ny temporry plug wire leling one ll wires hve een instlled nd routing onfirmed. Sprk plug wire instlltion AUGUST 2009 Pge 4C-

12 Sorpion Distriutor Sorpion Distriutor Exploded View Distriutor p 2 - Distriutor p srew (2) 3 - Rotor 4 - E lip 5 - Shft 6 - Bushing, upper shft 7 - Terminl lok srews (2) 8 - Terminl lok wshers (2) 9 - Distriutor hold down srew 0 - Distriutor hold down lmp - Terminl lok 2 - Distriutor housing 3 - Bushing, lower shft 4 - Wsher 5 - Distriutor ger 6 - Pin 7 - Gsket Sorpion Distriutor Removl. Verify tht ylinder No. is t TDC. 2. Remove the distriutor p nd set it side. Do not remove the sprk plug wires unless neessry. Lel eh plug wire y ylinder if the re removed. Pge 4C AUGUST 2009

13 3. Pint n indexing line on the inside of the distriutor housing to mrk the rotor position. - Indexing line - Rotor - Distriutor housing d - Intke mnifold 4. Remove olt nd hold down lmp. 5. Remove the distriutor nd the gsket from the intke mnifold. IMPORTANT: To ese instlltion, do not turn the engine over while the distriutor is removed. Sorpion Distriutor Disssemly. Remove the rotor from the distriutor shft y lifting stright up. 2. Remove roll pin with enter punh nd light hmmer. d Distriutor shft - Center punh - Roll pin Remove the wsher nd drive ger from the distriutor shft. 4. Remove the distriutor shft from the housing. 5. Chek for side ply etween shft nd distriutor housing ushings. Desription Distriutor shft to housing side ply 6. Chek the distriutor shft runout with dil inditor nd V loks. Desription Distriutor shft runout 7. Inspet the distriutor p for rks or ron trking. 8. Inspet the distriutor p terminls for orrosion nd terminl erosion. 9. Inspet the rotor for rks or ron trking. 0. Inspet the rotor for orrosion nd terminl erosion.. Reple ny omponents tht do not meet speifition. Sorpion Distriutor Assemly. Lurite distriutor shft with engine oil nd instll into the housing. Speifition 0.05 mm (0.002 in.) mximum Speifition 0.05 mm (0.002 in.) mximum Tue Ref No. Desription Where Used Prt No. 80 SAE Engine Oil 30W Distriutor shft Otin Lolly 2. Instll the tng wsher, the wsher nd the drive ger onto the shft AUGUST 2009 Pge 4C-3

14 3. Temporrily instll the rotor on the shft. Align the srie mrks on the ger, the housing, nd the rotor. 4. Instll the roll pin through the drive ger nd the distriutor shft. NOTE: A new drive ger will hve roll pin hole drilled on one side. 5. If instlling new drive ger:. Slide drive ger onto distriutor shft; lign hole in ger with hole in distriutor shft.. Chek the lerne etween the drive ger nd the distriutor housing. The drive ger must turn freely. Desription Distriutor ger to distriutor housing lerne Speifition 0.38 mm (0.05 in.). Using the hole in the drive ger nd shft s guides, drill through the other side of drive ger with 3/6 in. ride tipped drill. New distriutor ger instlltion - V lok - 3/6 in. drill it - Drive ger d - Distriutor ger to housing lerne d 2925 d. Instll the roll pin through the holes in the drive ger nd distriutor shft. e. Rehek the lerne etween the drive ger nd the distriutor housing. The drive ger must turn freely. Desription Driver ger to distriutor housing lerne 6. Align the distriutor shft keywys. 7. Instll the rotor onto the distriutor shft. The rotor tng must e ligned with the srie mrk. Speifition 0.38 mm (0.05 in.) - Indexing line - Rotor - Distriutor housing d - Intke mnifold d Sorpion Distriutor Instlltion. Verify tht ylinder numer one is t TDC. If not follow either of the following methods to position ylinder No. t TDC: IMPORTANT: Do not insert nything into sprk plug hole while turning the engine over.. Remove the No. sprk plug. Atth suitle soket nd drive to the rnkshft pulley nut. Ple finger over the plug hole nd turn the engine over y hnd until ompression is felt in the No. ylinder. Continue turning the engine over y hnd until the lok mounted timing pointer ligns with the timing mrk on the rnkshft pulley.. Atth suitle soket nd drive to the rnkshft pulley nut. Remove the left (when oserved from the rer of the engine) roker over nd turn the engine over y hnd until the No. ylinder intke vlve is fully losed. Continue turning the engine over y hnd until the lok mounted timing pointer ligns with the timing mrk on the rnkshft pulley. Pge 4C AUGUST 2009

15 2. Position the distriutor rotor so tht it would fire ylinder No.. Use the indexing line s referene. - Indexing line - Rotor - Distriutor housing d - Intke mnifold 3. Instll new gsket on the distriutor housing. IMPORTANT: Do not use the hold down lmp nd olt to fore the distriutor into position. 4. Slide the distriutor into the lok until it stops on its own. Do not fore the distriutor. IMPORTANT: Ensure tht the oil pump shft is properly engged. If the engine hs een tuned over fter disssemly it my e neessry to reposition the oil pump shft. 5. Rise the distriutor up from its initil stopping point nd rotte the rotor pproximtely /8 turn ounterlokwise. 6. Continue lowering the distriutor into the lok gently working the distriutor nd rotor so tht the oil pump shft nd mshft ger re properly engged. It my e neessry to rotte the rotor slightly until enggement is felt. 7. When properly instlled, the distriutor housing is in full ontt with the mhined relief in the intke mnifold. 8. Instll the hold down lmp over the distriutor nd olt it seurely to the engine surfe. Tighten the olt to speifition. Desription Nm l in. l ft Distriutor hold down lmp olt Connet ll ignition ontrol wiring. d Instll the distriutor p. Ensure tht the rotor is still pointing t the No. ylinder plug wire terminl.. Connet the sprk plug wires. Remove ny plug wire temporry leling when ll wires hve een instlled nd onfirmed with the engine's firing order. 2. Provide suffiient ooling wter to ll wter inlets. 3. Strt the engine nd onfirm proper opertion AUGUST 2009 Pge 4C-5

16 Notes: Pge 4C AUGUST 2009