FUEL SYSTEM 5 E BSO / SAV EMISSION FUEL SYSTEM

Transcription

1 FUEL SYSTEM 5 E BSO / SAV EMISSION FUEL SYSTEM

2 Tle of Contents Pge Identifiction E-1 Replcement Prts Wrning E-1 Torque Specifictions E-1 Specil Tools E-1 Cruretor Specifictions E-2 Cruretor Adjustment Specifictions E-2 Engine Specifictions E-2 Description E-3 Specil Notes E-3 Cruretor Top Cover E-3 Seled Idle Mixture Screws E-3 Metering Assemly E-4 Precutions E-5 Mintennce E-6 Flme Arrestor E-6 Fuel Filter E-6 Positive Crnkcse Ventiltion (PCV).... 5E-6 Trouleshooting E-7 Checking Ported Vcuum Switch nd Cruretor Vcuum Circuit for Correct Opertion E-7 Service Procedures E-8 Checking Positive Crnkcse Ventiltion (PCV) Vlve E-8 Removing Sels From Idle Mixture Screws E-9 Instlling New Sels E-9 Cruretor Instlltion E-10 Ported Vcuum Switch Instlltion E-10 Emissions System Connections E-11 Propne Assisted Idle Set Procedure.... 5E-12 Test Equipment E-14 Emissions Testing E-14 5E-0 BODENSEE EMISSION FUEL SYSTEM

3 Identifiction The Bodensee Emissions version of the Weer WFB cruretor hs vcuum fittings on the front side. Torque Specifictions Description l. in. l. ft. N m Cruretor to Mnifold Fuel Line to Cruretor Specil Tools Mercury Mrine Specil Tools Description Prt Numer Universl Cruretor Guge Tchometer Vcuum Fittings Replcement Prts Wrning! WARNING Electricl, ignition nd fuel system components on your MerCruiser re designed nd mnufctured to comply with U.S. Cost Gurd Rules nd Regultions to minimize risks of fire nd explosion. Use of replcement electricl, ignition or fuel system components, which do not comply with these rules nd regultions, could result in fire or explosion hzrd nd should e voided. Other Specil Tools Description Prt Numer Universl Cruretor Stnd TORX Screwdrivers (15,20&25) Otin Loclly Propne Bottle [14 oz. (400 grms)] Propne Enrichment Kit (Vrious Suppliers) Ported Vcuum Switch (PVS) Socket Wrench (Vrious Suppliers) Specil 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 cruretors will hve str shped socket in the hed of some screws. A TORX screwdriver must e used on this type of screw. The sizes used re numers 15, 20 nd BODENSEE EMISSIONS FUEL SYSTEM - 5E-1

4 Cruretor Specifictions Units of Mesurements In.(mm) Engine Model MCM 4.3LX Cr Type Weer WFB Mercury Numer (Mnufcturer Numer) Primry Jet Size Secondry Jet Size Metering Rod Numer Metering Rod Spring Color (9662) Nturl Cruretor Adjustment Specifictions Mke And Model Weer WFB Flot Level 1-9/32 (33) Flot Drop 2 In. (51) Pump Rod Hole Loction Numer 3 from end (Hole closest to lever pivot point) Accelertor 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 choke rod from lever hole. choke held closed nd choke rod is pushed down with top edge of rod even with ottom edge of hole. Engine Specifictions Model Thermostt Ignition Timing Idle Speed in Neutrl Propne Idle Speed (See Procedure) 4.3LX Alph 160 F (71 C) 10 BTDC 775 RPM 850 RPM 5E-2 BODENSEE EMISSION FUEL SYSTEM

5 Description The Bodensee Emissions system is designed to lower exhust emissions to meet regultions on the Bodensee. It consists of the following items: Positive Crnkcse Ventiltion (PCV) circuit, Ported Vcuum Switch (PVS) circuit, higher temperture thermostt [160 F (71 C)], nd specilly designed Weer WFB cruretor. Weer WFB cruretor is unique in design, s the min ody nd flnge re cst s one piece unit. This, long with the owl cover, mke up the two piece construction which is mde of light, durle luminum to dissipte het. There re two seprte flot circuits. Ech flot circuit supplies fuel to primry low speed circuit nd primry nd secondry high speed circuit. The owls re vented to the inside of the ir horn. A connecting vent pssge effects lnce of the ir pressure etween the two owls. The flot needle vlves re instlled t n ngle to provide the est possile seting ction on the needles. This provides etter needle response to flot movement, lso. The PVS circuit is used in conjunction with the idle circuit. When the engine is cold, the PVS circuit is closed. This shuts off metered ir-leed to the idle circuit, to mintin rich idle circuit for wrm-up. Once the engine wrms up [ pproximtely 128 F (54 C)], the PVS opens, llowing metered mount of ir to e mixed into the idle circuit. This lens the idle circuit to the proper operting ir-fuel rtio. The high speed circuits use stged step-up rods in the min metering jets to control the mount of fuel dmitted to the nozzles. The position of the step-up rod is controlled y mnifold vcuum pplied to the vcuum piston. A primry ir leed locted in the venturi cluster prevents rich condition or og s the high speed circuit is rectivted fter decelertion. Smll L shped metl ts, clled distriution t(s), re ttched to some venturi clusters nd protrude into the ir strem t the proper loction to id distriution of fuel on selected pplictions. The PCV circuit ventiltes crnkcse vpors (unurned gses) ck into the intke mnifold to e urned gin. Specil Notes IMPORTANT: Disssemly nd repir of the Bodensee Emissions cruretor is siclly the sme s the other Weer WFB cruretors. There re some internl nd externl differences tht re noted following: Cruretor Top Cover The cruretor top cover (ir-horn) hs vcuum fittings for connection to the Ported Vcuum Switch (PVS). - Vcuum Fittings Seled Idle Mixture Screws The idle mixture screws hve sels tht prevent tmpering with the idle mixture fter the mixture hs een properly djusted Screw Sels BODENSEE EMISSIONS FUEL SYSTEM - 5E-3

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

7 PISTON ASSEMBLY COVER IS HIGHER Precutions! WARNING Alwys disconnect ttery cles from ttery BEFORE working on fuel system to prevent fire or explosion.! WARNING Emissions Stndrd Be creful when clening flme rrestor nd crnkcse ventiltion hose: gsoline is extremely flmmle nd highly explosive under certin conditions. Be sure tht ignition key is OFF. DO NOT smoke or llow sources of sprk or open flme in re when clening flme rrestor nd crnkcse ventiltion hose ! WARNING Be creful when chnging fuel system components: gsoline is extremely flmmle nd highly explosive under certin conditions. Be sure tht ignition key is OFF. DO NOT smoke or llow sources of sprk or open flme in re while chnging fuel filter. Wipe up ny spilled fuel immeditely. PISTON BORE HAS A STEP ON EMISSIONS MODEL! WARNING Mke sure no fuel leks exist, efore closing engine htch.! CAUTION DO NOT operte engine without cooling wter eing supplied to wter pickup holes in ger housing or wter pickup inlet, or wter pump impeller will e dmged nd susequent overheting dmge to engine my result BODENSEE EMISSIONS FUEL SYSTEM - 5E-5

8 Mintennce Flme Arrestor Mintennce for the flme rrestor is the sme s stndrd engine (See the Weer WFB cruretor section of the pproprite MerCruiser Service Mnul). The only difference in the flme rrestor on n engine with the Bodensee Emissions system is in the vent hose rcket. This rcket hs fitting on one side only. Fuel Filter Mintennce for fuel inlet filters is the sme s stndrd engine (See the Weer WFB cruretor section of the pproprite MerCruiser Service Mnul). Positive Crnkcse Ventiltion (PCV) The Positive Crnkcse Ventiltion (PCV) vlve should e replced once yer. d c - PCV Vlve - Hose Stud - Vent Hose Brcket c - Vent Hose To Strord Vlve Cover d - NO VENT HOSE ON THIS SIDE 5E-6 BODENSEE EMISSION FUEL SYSTEM

9 Trouleshooting NOTE: Review the Description section of this mnul for n understnding of system opertion, efore trouleshooting the cruretor. Do not ssume tht prolem exists inside the cruretor without first eliminting other engine system components s potentil prolem res. Be sure to check the following items: Engine operting temperture (Proper Thermostt - See Engine Specifiction Chrt ). Correct ignition timing (See Engine Specifiction Chrt ). Cylinder compression. Ported Vcuum Switch (PVS) functioning properly. Use the following procedure to check for fulty Ported Vcuum Switch (PVS): Checking Ported Vcuum Switch nd Cruretor Vcuum Circuit for Correct Opertion NOTE: The engine must e cold efore performing the first 4 steps. 1. Strt engine. Disconnect the hose from the cruretor t the loction shown. 2. Plug the hose with your finger. You should not feel vcuum on the hose t this time Allow engine to run nd wrm up to norml operting temperture. Disconnect the hose gin nd check for vcuum. If PVS is functioning properly, there should e vcuum present t this time. If vcuum is not present, check to ensure tht hoses re properly connected nd re not crcked or plugged. Then, proceed to check the cruretor vcuum circuit. 4. Reconnect rer hose to cruretor. NOTE: The engine must e wrm efore performing the next step. 5. Strt engine nd llow it to rech norml operting temperture. 6. Disconnect the two hoses on the front of cruretor BODENSEE EMISSIONS FUEL SYSTEM - 5E-7

10 IMPORTANT: Ensure tht engine is running t 775 RPM or elow. This ensures tht the cruretor is not running on the Off-Idle circuit. 7. Connect tchometer to the engine. 8. Plug the vcuum ports on the front of the cruretor. Be sure to only plug one port t time. When vcuum port is covered, the engine RPM should increse. Repet test on the other port. If vcuum is not present, vcuum port my e plugged. Clen vcuum ports nd repet the entire test. Service Procedures Checking Positive Crnkcse Ventiltion (PCV) Vlve 1. Strt engine nd llow it to rech norml operting temperture. 2. Remove PCV vlve from vlve cover. Plug the opening with your finger. A vcuum should e felt. 3. Stop the engine. 4. Shke the vlve to ensure tht the internl components re free to move When test is complete nd PVS is determined to e functioning properly, reconnect ll hoses in vcuum circuit. 5E-8 BODENSEE EMISSION FUEL SYSTEM

11 Removing Sels From Idle Mixture Screws 2. Align the opening in the plug with the t on the cup nd push down until it snps in plce.! WARNING Avoid fire or explosion. Using cutting wheel to cut the sels will cuse sprks, which will ignite ny fuel tht is present. Ensure tht there is no fuel present nd tht cruretor is removed from engine prior to cutting the sels from the cruretor idle mixture screws. 1. Remove cruretor from the engine. 2. Drin ll fuel from the cruretor. 3. Using cutting wheel, mke cut on oth sides of the sel csing. Using suitle device, pry the plug from the inside of the sel. Once the plug is removed, the idle mixture screw cn e removed nd the sel csing cn e removed. - Opening In Plug - T On Cup Instlling New Sels 1. Instll new sel cup, spring nd idle mixture screw. IMPORTANT: Do not instll the sel plug until the Propne Assisted Idle Mixture Adjustment procedure hs een completed BODENSEE EMISSIONS FUEL SYSTEM - 5E-9

12 Cruretor Instlltion 3. Instll new cruretor s follows:. Plce new gsket on dpter plte.. Instll cruretor nd throttle rcket nd secure with new ttching hrdwre. Torque fsteners to 132 l.in. (15 N m). c. Connect fuel line. To prevent over-tightening, hold fuel inlet nut with suitle wrench nd tighten fuel line connector securely. c d Ported Vcuum Switch Instlltion! CAUTION Be creful not to rek off fittings when instlling the ported vcuum switch (PVS) in the following step. NOTE: A specil tool is ville to instll the PVS. Refer to the Tool Chrt t the eginning of this mnul. 1. If removed, instll ported vcuum switch (PVS) into reducer ushing. Apply Loctite Pipe Selnt with Teflon to threds efore instlling. Tighten it securely nd position the fittings towrd ck of engine s shown Reducer Bushing - Ported Vcuum Switch (PVS) Throttle Brcket - Attching Hrdwre c - Fuel Line d - Fuel Inlet Nut 5E-10 BODENSEE EMISSION FUEL SYSTEM

13 Emissions System Connections 1. Instll the positive crnkcse ventiltion (PCV) vlve in the port vlve cover. 2. Connect hose to PCV vlve. Connect opposite end of hose to fitting on front of cruretor. 3. Connect hoses to ported vcuum switch (PVS) s shown. d c c d - Ported Vcuum Switch - Hoses (Switch To Y-Fitting) c - Hoses (To Front Side Of Cruretor) d - Hose (Y-Fitting To Bck Side Of Cruretor) c PCV Vlve - Hose c - Cruretor Fitting (Connect Hose Here) BODENSEE EMISSIONS FUEL SYSTEM - 5E-11

14 IMPORTANT: The hose tht runs from the T-Fitting to the ck side of the cruretor must e routed eneth the throttle linkge s shown in the following illustrtion. Use cre to ensure tht the hose does not ru ginst linkge Propne Assisted Idle Set Procedure! WARNING Avoid fire or explosion. Oserve the following precutions when performing this procedure. Do not operte the engine without the flme rrestor instlled, ove the speeds listed in this procedure. Propne is extremely flmmle nd explosive. Ensure tht the following test is performed in well ventilted re with the engine htch 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 plced into the cruretor nd the engine hs een strted. Keep fire extinguisher ville when performing this test. NOTE: This test must e performed ny time the cruretor hs een disssemled nd internl components hve een distured or the idle mixture screws hve een tmpered with. The test should lso e performed if other component prts of the emissions system hve een ltered, repired, or replced IMPORTANT: Ensure tht the PVS is functioning properly efore performing this procedure. 1. As strting point, set oth idle mixture screws 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. - T-Fitting - Hose - T-Fitting T Bck Of Cruretor 5E-12 BODENSEE EMISSION FUEL SYSTEM

15 4. Insert specil Y -Adpter hoses into cruretor s shown. Plce the hoses ehind the choke plte to help hold them in plce. 8. Relese the propne flow vlve nd llow engine speed to stilize. Slowly djust the mixture screws y equl mounts, pusing etween djustments to llow engine speed to stilize, to chieve 775 RPM Connect 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 reched. When too much propne is dded, engine RPM will decrese. Fine tune the metering vlve to otin the highest RPM Press the propne flow vlve. Engine RPM should increse to 850 RPM. If it does not, repet steps 5 thru 7. - Propne Flow Vlve - Propne Metering Vlve With propne still flowing, djust the idle speed screw (not the mixture screws) to otin 850 RPM. Agin, fine tune the propne metering vlve to otin the highest engine RPM. If there hs een chnge in the mximum RPM, redjust the idle speed screw to 850 RPM If fter performing the ove procedure severl times, the correct results cn still not e otined, check the following: PVS not working properly. Incorrect flot level. Vcuum leks BODENSEE EMISSIONS FUEL SYSTEM - 5E-13

16 11. Once the idle speed nd mixture djustment is correct, instll the sel plugs over mixture screws. Ensure the opening in plug snps into the t in the cup. c Emissions Testing NOTE: This test will e performed y n uthorized gency for the re tht the ot will e operted. This gency 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 crried ord the vessel t ll times. The following steps will explin how these proes re to e instlled Screw Sel - T In Cup c - Opening In Cup 12. Reinstll the flme rrestor. Test Equipment The following equipment is needed to perform n emissions test on this engine: Test Proes (Supplied in Kit). Test Proe Collector (Testing Agency). Exhust System Anlyzer (Testing Agency). - Exhust Test Proes (2) - Exhust Elow Adpter Fittings (2) 1. Remove plugs from oth exhust elows. - Plugs (Port And Strord Elows) Exhust Proe Collector - To Exhust Anlyzer E-14 BODENSEE EMISSION FUEL SYSTEM

17 2. Instll exhust elow dpter fittings into elows. Apply Loctite Pipe Selnt with Teflon to threds tht go into elow. Tighten securely. 3. Insert exhust test proes into fittings nd tighten securely. NOTE: Be certin to plce 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 specil design fetures nd specil tuning to minimize the emission output from the engine. You should follow: Recommended mintennce schedules prticulrly s to the ignition system. Proper engine tuning procedures to ensure these fetures remin in good operting order. Proper steps to mintin the engine within specifiction. - Fittings - Exhust Test Proes The instructions in the Emissions Kit provide the necessry informtion to properly convert the engine to meet the pplicle Bodensee Regultions. There is nother item within the regultion tht is eyond the control of Mercury Mrine. This item is relted to the fuel filling system on the ot. The requirements for the fuel filler neck 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 neck shll e durle nd designed so tht modifictions re not possile. A durle, legile plte shll e mounted on the ot ner the fuel filler neck. This plte shll red: UNLEADED GASOLINE ONLY. Any questions out the fuel filler neck requirement nd vilility of the required components should e directed to the ot mnufcturer. 4. When exhust emissions test is complete, remove test proes nd dpter fittings nd reinstll the plugs. Apply Perfect Sel to threds efore instlling. Tighten them securely BODENSEE EMISSIONS FUEL SYSTEM - 5E-15

18 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 5E-16 BODENSEE EMISSION FUEL SYSTEM