Outboard V6 EFI Technician’s Guide 1
Table of Contents Section 1 – General Information Section 2 – 1987-2001 2.4L/2.5L EFI Section 3 – 1995-2001 3.0L EFI Section 4 – 2002 & Newer 2.5L/3.
Section 1 - General Information 90-898303 1-1 3
Table of Contents Table of Contents ............................................................................................. 2 Speed/Density System ..................................................................................... 3 Speed/Density Theory ................................................................................. 3 Fuel Injection System Function.........................................................................
Speed/Density System Notes Speed/Density Theory _______________________ Outboard EFI engines operate on the fuel injection strategy called “Speed/Density”. This means that the ECM primarily looks at the engine’s speed and the intake manifold’s air density in order to calculate the correct amount of fuel to inject. _______________________ The engine requires an air/fuel mixture of approximately 14:7 to 1 in the combustion chambers.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ Fuel Injection System Function Fuel is delivered directly to the engine by way of fuel injectors. These injectors are provided with a constant supply of fuel delivered to the fuel rail. The injectors are opened and closed electronically by the Electronic Control Module (ECM).
Section 2 - 1987-2001 2.4/2.
Table of Contents Table of Contents ............................................................................................. 2 2.4 / 2.5L System Block Diagram W/ADI Ignition ............................................. 4 2.5L System Block Diagram w/CDM Ignition .................................................... 6 1987-1995 2.4L / 2.5L Fuel Flow Diagram ....................................................... 7 1996-2001 2.5L Fuel Flow Diagram ..........................................................
Miscellaneous Checks ....................................................................................36 Miscellaneous Checks ....................................................................................37 Mechanical Checks ....................................................................................37 Fresh Quality Fuel ......................................................................................37 Low Battery Voltage ...............................................................
2.4 / 2.
2.
1987-1995 2.4L / 2.
Notes 1996-2001 2.
90-898303 2-9 14
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 2.4/2.5L Fuel Flow Component Description Pulse Fuel Pump The pulse fuel pump operates through alternating crankcase pressure to deliver fuel through the water-separating filter to the vapor separator. • Fuel pressure @ Idle – 2-3 psi (Minimum – 1 psi).
Final Filter Notes 1996–2001 2.5L/1995–2001 3.0L _______________________ The final filter is located below the electric fuel pump in the vapor separator. The filter collects debris and prevents them from flowing through the electric pump and into the fuel rail and injectors. 1987–1995 2.4L/2.5L _______________________ _______________________ _______________________ The final filter is located above the electric fuel pump.
Notes Fuel Pressure Regulator _______________________ The fuel pressure regulator is located on top of the vapor separator and is continuously regulating fuel pressure produced by the electric fuel pump. The electric pump is capable of producing90 psi (621 kPa) of fuel pressure. _______________________ NOTE: Units with external electric fuel pump limits pressure to 36–39 psi. _______________________ NOTE: Units with internal electric fuel pump limits pressure to 34–36 psi.
A four wire harness connects the fuel injectors to the ECM. The RED wire is at 12 volts and connects to all injectors. The BLUE, YELLOW and WHITE wires each go to a pair of injectors and are normally at 12 volts for a zero differential. To fire the injectors this voltage is brought down to near ground creating a potential across the injectors.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ EFI Electrical Components EFI Electronic Control Module The ECM continuously monitors various engine conditions (temperature, throttle opening) and climate conditions (induction air temperature, barometric pressure, and altitude level) needed to calculate fuel delivery (pulse width length) of injectors.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ THROTTLE POSITION SENSOR (TPI) _______________________ The TPI transmits information to the ECM during low speed and mid range operation, related to throttle angle under various load conditions. TPI adjustment is a critical step in engine set up (Section 2C).
ELECTRIC FUEL PUMP Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ The ECM contains a fuel pump driver circuit that provides power to the electric fuel pump (2 speeds). The fuel pump does not have its negative terminal (-) “red/purple wire” grounded to the pump housing.
DETONATION CONTROL SYSTEM FUNCTION 1) Combustion noise (or vibration) excites the piezoelectric circuit located inside the detonation sensor, which transmits a voltage to the control module. 2) When cylinder number two ignition primary fires, it signals the controller to look at a one millisecond window of sensor output, which it retains as a reference level of combustion “background noise.
Notes 2000–2001 Models with CDM Ignition _______________________ The Detonation control system will only retard the timing approximately 1-2 degrees (uses same system as shift stabilizer on carburetor models). _______________________ The Detonation Control System consists of a detonation control sensor located on the cylinder head and a detonation control module mounted on the engine.
1987 - 1995 2.4L & 2.5L - Fuel Pump Test VOLTAGE TEST CHART Engine Mode BLACK Meter Lead to Engine Ground; RED Meter Lead to: Approximate Voltage Reading If Approximate Voltage is not obtained, this indicates: If reading is below 12 volts, the battery is bad, discharged or has bad connection(s). 1. All models (+) terminal of fuel pump 12 – 13.5 volts 2. Ignition key in “OFF” position. (– ) terminal of fuel pump. Same reading should be obtained as reading in check No.
1996 and newer 2.5L - Fuel Pump Test VOLTAGE TEST CHART Engine Mode BLACK Meter Lead to Engine Ground; RED Meter Lead to: Approximate Voltage Reading If Approximate Voltage is not obtained, this indicates: If reading is below 12 volts, the battery is bad, discharged or has bad connection(s). If reading is higher than 13.5 volts, the battery is over-charged 1. All models (+) terminal of fuel pump 12 – 13.5 volts 2. Ignition key in “OFF” position.
Ignition Systems 90-898303 2-21 26
1987-1999 2.4L/2.
Notes Description _______________________ The V-6 outboard ignition system is alternator-driven with distributor-less capacitor discharge. Major components of the system are the flywheel, stator assembly, trigger assembly, 2 switch boxes, 6 ignition coils and 6 spark plugs. _______________________ The stator assembly is mounted below the flywheel and has 4 capacitor charging coils.
Notes 2.4L & 2.5L - Troubleshooting Tips _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 1) Intermittent, weak or no spark output at 2 spark plugs (one plug from each bank of three cylinders) usually is caused by a bad TRIGGER. 2) A SWITCH BOX can also cause 2 cylinders (1 each bank) to lose spark.
9) Repeat failures of the same electrical component could be caused by other electrical components. - If one circuit in a switch box keeps failing, it could be the result of high resistance in the primary of a coil, primary lead between the switch box and coil or high resistance on the coil primary ground wire. - If same switch box keeps failing, it could be because of a random open circuit in the trigger.
Idle Stabilizer Shift System Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ a) b) c) d) Inner
TEST FOR PROPER FUNCTION OF IDLE STABILIZER SHIFT SYSTEM Connect timing light to number one spark plug lead (top, starboard bank). Start the engine and allow it to idle at specified engine RPM. Place outboard in gear while monitoring ignition timing. Timing will advance three degrees if system is functioning correctly. TROUBLESHOOTING IDLE STABILIZER SHIFT SYSTEM When outboard is idling IN NEUTRAL, shift switch circuit is in the OPEN position and system is INACTIVE.
2000-2001 V6 2.0L/2.
Theory of Operation Notes The V– 6 Outboard CDM ignition system is alternator– driven with distributor– less capacitor discharge. Major components of the system are the flywheel, stator assembly, trigger assembly, control module, 6 CDM assemblies and 6 spark plugs. The stator assembly is mounted below the flywheel and has 3 capacitor charging coils. The flywheel is fitted with permanent magnets inside the outer rim.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Capacitor Charging #4, #5 & #6 CDMs The flywheel rotates the permanent magnets past the capacitor charging coils causing the coils to produce AC voltage (260-320 volts). The opposite voltage pulse is then conducted to the CAPACITOR DISCHARGE MODULES (CDM), where it is rectified (DC) and stored in a capacitor.
Control Module Notes The control module provides rev– limit (carb models), bias control, shift stabilizer, idle stabilizer, injector timing signal (EFI models), and low oil warning. _______________________ _______________________ On carburetor models, the rev– limiter affects the cylinders in the following sequence 2– 3– 4– 5– 6– 1. As the engine RPM exceeds the maximum specification (5900 ± 100), the control module will retard the timing on cylinder #2.
Notes _______________________ _______________________ _______________________ EFI Injector Timing Signal Test Use DDT to monitor injector timing signals. EFI Detonation Control System _______________________ The Detonation Control System will only retard the timing approximately 1-2 degrees (uses the same system as shift stabilizer on carburetor models). _______________________ Use DDT monitor Knock Volts. _______________________ CDM Stop Diode Troubleshooting _______________________ 2.0/2.
1992–1999 150 EFI/175 EFI Wiring Diagram BLK = BLACK TAN = TAN BLU = BLUE VIO = VIOLET BRN = BROWN WHT = WHITE GRY = GRAY YEL = YELLOW GRN = GREEN PUR = PURPLE RED = RED 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) Water Temperature Switch 2Warning Module Starter Solenoid Starter Motor Air Temperature Sensor Electronic Control Unit Fuel Pump Injectors 12 Volt Battery Rotational Sensor Water Sensing Warning Module Water Separating Filter Throttle Position Sensor Idle Stabilizer Engine Har
1992–1999 200 EFI Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 90-898303 2-34
1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) Detonation Sensor Detonation Module Water Temperature Switch Warning Module Starter Solenoid Starter Motor Air Temperature Sensor Electronic Control Module Fuel Pump Injectors 12 Volt Battery Rotational Sensor Water Sensing Warning Module Water Separating Filter Throttle Position Sensor Idle Stabilizer Engine Harness Connector Voltage Regulator (2) 20 Ampere Fuse Outer Switch Box Inner Swi
Miscellaneous Checks Notes _______________________ Mechanical Checks Marine engines are, by the nature of their environment, engineered to be trouble-free, durable power plants. The experienced mechanic, when investigating a possible marine engine problem, will isolate boat related support systems from the marine engine. This can be accomplished through the use of a remote fuel tank filled with fresh fuel and utilizing a known good fuel line/primer bulb assembly.
Notes Low Battery Voltage _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Low battery voltage can cause EFI system to deliver fuel in an inconsistent manner.
2.4L & 2.5L - Preliminary Steps Notes Ignition Spark Check _______________________ Purpose: This test determines if the ignition system is delivering usable spark to the spark plugs. By performing this test, the probable cause can be isolated to either the ignition system or fuel system. _______________________ Procedure: _______________________ _______________________ _______________________ 1) Disconnect all spark plug wires from spark plugs.
Notes _______________________ _______________________ _______________________ _______________________ IMPORTANT: The presence of a good spark will not necessarily indicate condition of timing. Ignition timing may be off far enough to prevent the engine from starting, but still allow a good spark to be present in the spark gap tester. Ignition system failure (switch box, stator, trigger, etc.) can cause fuel delivery problems.
2.4L & 2.5L - Throttle Position Sensor Adjustment Notes _______________________ IMPORTANT: Engine harness MUST BE disconnected from the EFI tester 91-11001A2 and reconnected in the normal running configuration in order to test or adjust the throttle position sensor. IMPORTANT: TPS can be adjusted using a digital meter. Analog (needle) type may be used although it may be difficult to read the low voltage setting accurately with most meters. 1) Disconnect TPS from EFI harness.
Notes 5) Loosen screws (1) securing TPS to manifold. _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 6) Rotate TPS fully clockwise (holding throttle shaft in closed position). Voltmeter should read .200 - .300.
13) Disconnect wires and remove sensor.
Hard To Start 2.4L , 2.5L , EFI Engines (Cold Weather) There have been occasional reports of hard starting EFI engines (150 to 200 HP 2.4 & 2.5 Litre) in cold weather. The symptom normally is that the engine will start and run good in warm weather (above 50° F., 10° C). When the temperatures drop, typically the engine will crank over, start and stall. After several attempts the engine starts runs rough for one or two minutes then smoothes out runs and starts good for the rest of the day.
Injector Electrical Harness Test Notes _______________________ _______________________ Purpose: This test will determine if electrical or fuel delivery problem exists during the fuel delivery process by checking for open circuits in injector harness. 1) With outboard in water, start and allow to warm up. Raise engine speed to 2000-2500 RPM. Remove spark plug leads one at a time and note RPM change. Determine nonworking (no RPM change) cylinder. Stop engine.
ECM Injector Driver Test Notes To verify that the ECM is operating the injector pairs, connect test harness (91-833169) between manifold connector and engine harness. Start engine. _______________________ Use DVA meter (91-99750). Set DVA to 200 scale. Connect BLACK meter lead to engine ground and RED test lead to each BLUE, WHITE or YELLOW female bullet connector. _______________________ Normal voltage for a 2.4L – 2.5L engines will be 25 to 60 volts. Voltage will vary with RPM.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Marine Diagnostics 824003 Fuel ECM OVERVIEW The systems diagnostic cartridge contains a diagnostic program for the Fuel ECM that allows the technician access to all of the diagnostic capabilities available from the Fuel ECM.
824003 Fuel ECM Notes _______________________ ADAPTER CABLES _______________________ 84-822560A5 _______________________ _______________________ _______________________ _______________________ _______________________ a) 84-822560A5 _______________________ DIAGNOSTIC PORT LOCATIONS IMPORTANT: Engine must be OFF before connecting the DDT adaptor cable to the ECM. 1) Connect the DDT adaptor cable to the ECM diagnostic port as shown. Attach the battery clips to a 12v battery.
Notes _______________________ Injector Test _______________________ PROCEDURE _______________________ For these procedures, refer to engine setup illustrations 1 and 2 on the following page.
5) Attach the Fuel Pressure Gauge to the fuel pressure test fitting. Turn the ignition key switch to the ON position and observe the fuel pressure reading after the pump driver times out (15 to 30 seconds). 6) Refer to the following section labeled Multi Test. From the Marine Diagnostic menu screen, select 3–Injector Test. From the Injector Test menu, select 1 –Multi Pulse Test. Use the ∀ key to increment the number of cycles in test to 50. Select the Ο key to move to the total on-timemilliseconds.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Multi Pulse Test 1) . From the INJECTOR TEST MENU screen, press 1. The MULTI– PULSE TEST screen will appear. The cursor will be positioned in the Cycles in Test field.
2.5L EFI Scan Data Worksheets 824003 ECM Data Monitor 824003 ECM Engine RPM IDLE 1500 3000 Coolant Temp. TPS Knock Volts Injector A Msec Injector B Msec Injector C Msec Atmosphere PSI MAP PSI Pump Amps Status Switches Trigger C TPS Coolant Temp. Pump Amps Air Temp.
Non-Programmable - ECM History 14632A1 Notes _______________________ _______________________ Original 1987 220 Magnum EFI/Laser XRi. Identification: The part number is hand written in black ink on the back plate. Engine re-quires inductor spark plugs. Has some improved RFI shielding after ECM S/N 5540 – Dated 2/11/87 - Engine serial number 0B197682. 14632A6 _______________________ _______________________ _______________________ _______________________ The latest and best 220 calibration.
Notes _______________________ 14632A15 - SST 824003A14 1991 175 Magnum EFI/XRi - 2.4 litre. _______________________ First ECM that requires the TPI to be set at .250 volts. Problem with the circuit not grounded to the housing - screws not tightened - suspect date code 9043 thru 9049 - engine runs rich - tester will not detect the poor internal ground stock inspected by the vendor and a black dot is applied after the part number.
Programmable - ECM History PROM Identification PROM ID Year Engine Type ECM Type ECM Service P/N Mercury Racing 2.0 – 3.0 Litre Not Available 94 2.0L Hi Perf Fuel 11350A26, 29 2615 95 2.0L Hi Perf Fuel 11350A34, 45 2612 95 2.0L Hi Perf Fuel 11350A54 2613 or 2650 95 2.0L Hi Perf Fuel 11350A53 2514 Service 2.4L Hi Perf Fuel 11350A40 Not Available 94 2.5L ROS Fuel 11350A30, 32 2509 95-96 ½ 2.5L ROS Fuel 11350A35, 36 2718 96 2.5L ROS Fuel 11350A62 2511 95 2.
PROM Identification (Cont.) PROM ID Year Engine Type 2.5 Litre ECM Type ECM Service P/N E683 or E556 94-95 200 2.5L XRi Fuel 824003-1, A1 A7C0 94-95 175 2.5L Xri Fuel 824003-2, A2 E57A 94-95 150 2.5L Xri Fuel 824003-4, A4 8714 95 200 PRO MAX Fuel 824003-5, A5 C9C2 or AD49 95 225 PRO MAX Fuel 824003-6, A6 A470 95 150 PRO MAX Fuel 824003-7, A7 5AA0 or 4227 96 200 2.5L XRi Fuel 824003-8, A8 436F or C2A0 96 175 2.5L Xri Fuel 824003-9, A9 1BB6 or 24C5 96 150 2.
Section 3 - 1995-2001 3.
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 1995-2001 3.0L Fuel Flow ................................................................................4 EFI Electrical Components ...............................................................................5 1995-2001 3.0L .......................................
1995-2001 3.0L Fuel Flow a) b) c) d) e) f) g) h) i) j) k) l) m) n) Fuel Injectors Fuel Rail o) p) q) r) Fuel Rail Pressure Port Fuel Pressure Regulator Manifold Hose Fuel Pressure Regulator To Starboard Bleed Junction Block To Port Bleed Junction Block Bleed System Filter MAP Sensor (3.
EFI Electrical Components Notes 1995-2001 3.0L _______________________ SENSOR INTERACTION WITH ECM _______________________ The ECM relies on sensor feedback to provide proper fuel rates and timing advance for optimum engine performance under all conditions. _______________________ _______________________ Should a sensor fail, the ECM will try to compensate for lack of sensor information by providing predetermined fuel rates and timing advance for average conditions.
Notes _______________________ _______________________ An overheat condition will occur if engine temperature exceeds 200° F (93° C). A constant warning horn will sound as long as the overheat condition exists. If the overheat condition should occur at wide-open-throttle, the engine RPM will be reduced to 3000. The engine will return to normal operating condition when the temperature drops below 200° F (93° C). _______________________ The temperature sensor can be tested using a digital volt/ohm meter.
INDUCTION MANIFOLD The induction manifold is a common plenum chamber for accurate pressure measurement. It contains 4 throttle shutters (*see below) on 2 throttle shafts. The shutter opening (idle air opening) can be adjusted during EFI set-up procedure. The manifold contains the fuel rail, injectors, throttle position sensor and air temperature sensor. A fuel rail pressure port is located on the fuel pressure regulator. • 3.0L 1995– 1999 225HP 2 shutters • 3.0L 2000– 2001 225HP 4 shutters • 3.
3.0L Fuel Pump Test VOLTAGE TEST CHART Engine Mode All Models Black Meter Lead To Engine Ground, Red Meter Lead To: (+) terminal of fuel pump. Approx. Voltage Reading 12-13.5 Volts If approx. Voltage Is Not Obtained, This Indicates: If reading is below 12 volts, the battery is bad or discharged, or a bad connection(s) on battery harness. If reading is higher than 13.5 volts, the battery is overcharged. Ignition key in “OFF” position. (-) terminal of fuel pump.
3.
1995-2001 3.
Theory of Operation Notes Ignition current is generated by the stator under the flywheel. The stator consists of six bobbins - one for each cylinder. The positive current wave charges the capacitor in the capacitor discharge module (CDM). The electronic control module (ECM) activates the switching device (SCR) in the CDM which allows the capacitor to discharge, causing the spark to occur. Ignition timing is regulated by the ECM which receives status input from a variety of sensors.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Warning control of LOW-OIL, WATER SEPARATOR and OVER-HEAT conditions.
STATOR Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ a) Stator b) Bobbins Stator has 6 charging bobbins – 1 bobbin for each ignition module. _______________________ _______________________ Each stator bobbin charges the ignition capacitor in each module.
Notes FLYWHEEL _______________________ Contains two magnets which charge stator bobbins. _______________________ _______________________ Flywheel has 22 teeth on outside rim which, by passing through crank position sensor’s magnetic field, informs the ECM of engine RPM and crankshaft angle. _______________________ CRANK POSITION SENSOR _______________________ Contains a permanent magnet and is positioned 0.040 ± 0.020 (1.02mm ± 0.51mm) from the flywheel teeth.
SHIFT INTERUPT SWITCH a) Shift Interrupt Switch A shift interrupt switch is mounted below the shift cable on the PORT side of the engine. 1995/1996/1997 MODEL 3.0 Litre WORK/225 Carb/225 EFI/250 EFI – When shift interrupt switch is activated, the ECM retards ignition timing to 20° ATDC. If switch is activated for longer than 2 seconds, the ECM detects switch failure and returns ignition timing to normal. 3.
_______________________ 225 EFI/250 EFI Warning Panel (3 Function Gauge) _______________________ Operation of Warning Panel _______________________ _______________________ When the ignition key is initially turned on, the warning horn will sound (beep) for a moment as a test to tell you the system is working. Failure of this test sound (beep) indicates a problem with the outboard or warning panel.
ENGINE OVER-SPEED Notes The engine over-speed protection system is activated when the engine speed exceeds the maximum allowable RPM. Anytime the engine over-speed system is activated, the warning horn begins beeping and the Engine Overheat and Low Oil Indicator Lights will turn on and alternately flash. In addition, the system will automatically reduce the engine speed to within the allowable limit by retarding the ignition timing.
3 Function Gauge Wiring a) b) c) d) e) f) g) h) i) j) Connect TAN/BLACK to TAN/BLACK Connect TAN/WHITE to TAN/WHITE Connect PINK/LT. BLUE to PINK/LT.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Injector Test PROCEDURE For these procedures, refer to engine setup illustrations 1 and 2 on the
Injector Test (Cont.) 5) Attach the Fuel Pressure Gauge to the fuel pressure test fitting. Turn the ignition key switch to the ON position and observe the fuel pressure reading after the pump driver times out (15 to 30 seconds). 6) Refer to the following section labeled Multi Test. From the Marine Diagnostic menu screen, select 3–Injector Test. From the Injector Test menu, select 1 –Multi Pulse Test. Use the ∀ key to increment the number of cycles in test to 50.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Multi Pulse Test 1) From the INJECTOR TEST MENU screen, press 1. The MULTI– PULSE TEST screen will appear. The cursor will be positioned in the Cycles in Test field.
Single Pulse Test 1) From the INJECTOR TEST MENU screen, press 2. The SINGLE PULSE TEST screen will appear. The cursor will be positioned in the On-Time (MS) field. 2) Use the υ and ∀ keys to adjust the time up or down. This will be the time the injector is to be ON during the test. The number must be between 0 and 1000 milliseconds. 3) 3. Use the = and Ο keys to move the cursor to the Adj-Increment field. 4) Use the υ and ∀ keys to set the adjustment.
3.
Ignition ECM Data Monitor IGNITION ECM IGNITION ECM IDLE 1500 3000 ENGINE RPM COOLANT TEMP TPS SPARK ANG STATUS SWITCHES WATER LEVEL HISTORY 0-1000 LOW OIL SW 1000-2000 RPM LIMITER 2000-3000 TPS 3000-4000 COOLANT TEMP 4000-5000 FUEL ENR 5000-RPM LIMIT OVER TEMP RPM LIMIT TIME TRIGGER SIG ECM RUN TIME SHIFT SWITCH OVER TMP TIME KNOCK HIST BREAK IN TIME COOL SNR HIST KNOCK TIME TPS SNR HIST RPM LIMIT CNT PROM ID ECM PART# PROM ID #1, #5, LED INDICATORS #2, #6, ILLUMINATED #3
3.0L PROM ID Chart PROM ID YEAR ENGINE TYPE ECM TYPE ECM SERVICE PART# 0002 FFFE FFFE FFFE FFFE FFFE FFFE FFFE FFFE FFFE C306 C206 E206 F206 E506 F506 E216 F216 E216 F226 C307 C207 E207 F207 E507 F507 E207 F217 E507 F517 EA07 FA07 EA17 FA17 E208 F217 E508 F517 C309 E500 F200 F500 94 94 95 95 95 95 95 95 95 95 96 96 96 96 96 96 96 Service 96 Service 96-1/2 Service 96-1/2 Service 97-98 97-98 97 97 97 97 97-1/2 97-1/2 97-1/2 97-1/2 97-1/2 97-1/2 97-1/2 97-1/2 98 97-1/2, 98 98 97-1/2, 98 99 00 00 00 3.
3.0L PROM ID Chart (Cont.) PROM ID Year Engine Type 3.0 Litre DFI ECM Type ECM Service P/N PROM ID 0102 97 200 DFI Ign-Fuel 828557-1 97-1/2 200 DFI Ign-Fuel 850270-6 ECM ID 4150 CALIB ID 0102 ENGINE ID 0101 PROM ID 0105 ECM ID 0102 CALIB ID 0105 ENGINE ID 0102 NOTE: For 1998 and newer see SYSTEM INFO fo correct ECM ID.
Section 4 - 2002 & Newer 2.5L/3.
Table of Contents Table of Contents ............................................................................................. 2 Table of Contents ............................................................................................. 2 2002 2.5L/3.0L Fuel Flow Diagram................................................................... 4 Fuel Flow Component Description.................................................................... 5 Pulse Fuel Pump (d) ..........................................
Guardian Protection System ...........................................................................36 Guardian System Operation with Gauges..................................................36 Guardian System Activation .......................................................................37 Smartcraft Data Worksheet.............................................................................38 Data Monitor – Two Stroke EFI ..................................................................
2002 2.5L/3.
Fuel Flow Component Description Notes _______________________ Pulse Fuel Pump (d) _______________________ The pulse fuel pump operates through alternating crankcase pressure to deliver fuel through the water separating filter to the vapor separator. Fuel _______________________ pressure @ Idle: 2 – 3 psi (13.8 – 20.7 kPa) [Minimum – 1 psi (6.9 kPa)]. Fuel Pressure @ Wide-Open-Throttle: 6 – 8 psi (41.4 – 55.2) [Minimum: 4 psi (27.6 _______________________ kPa)].
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Fuel Injectors (c) The fuel injectors are located on the fuel rail. The injector valve body consists of a solenoid actuated needle and seat assembly. The injector receives signals from the EFI Electronic Control Module. These signals determine how long the needle is lifted from the seat (pulse width) allowing a measured fuel flow.
Operation of Oil Injection System The oil injection system delivers oil mixture on engine demand, from 120:1 at idle to 50:1 at wide open throttle. Oil is stored inside a remote oil tank in the boat. This tank holds enough oil for approximately 150 gallons of fuel at wide open throttle. Crankcase pressure forces oil from the remote oil tank into the engine oil reservoir. The engine oil reservoir feeds oil to the oil pump.
Oil Injection Flow System a) b) c) d) e) f) g) h) i) j) Remote Oil Tank Oil Pickup Tube Filter 4 Psi Check Valve Oil Reservoir Low Oil (Float) Sensor (Inside Reservoir) Vapor Separator Tank Oil Inlet To Oil Pump Oil Injection Pump Oil Outlet Hose to Vapor Separator Tank 90-898303 4-8
Oil Injection Components Notes REMOTE OIL TANK (A) _______________________ Holds 3 gallons (11.5 liters) of oil. _______________________ NOTE: Some boats may be equipped with optional 1.8 gallon (7.0 liters) oil tank. The tank is pressurized by air from crankcase pressure thus forcing oil up the outlet hose to the oil reservoir on engine.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ Priming The Oil Pump NOTE: If a new powerhead is being installed or oil hoses/oil pump has been removed, it is recommended all air be purged from oil pump/oil lines using gearcase leakage tester (FT-8950)(a). Connect the leakage tester to the inlet t-fitting on the onboard oil reservoir. While clamping off the inlet hose, manually pressurize the reservoir to 10 psi.
METHOD 3 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – OIL PUMP PRIME This method fills the oil pump, oil supply hose feeding pump, and oil hoses going to the crankcase and air compressor. Notes _______________________ _______________________ Refer to procedure in the Technician Reference Manual provided with the Digital Diagnostic Software Cartridge Part. No. 91-880118--1.
Notes _______________________ _______________________ _______________________ Prime the oil injection pump as follows: 1) Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until it fells firm. 2) Turn the ignition key switch to the “ON” position. 3) Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times. This will automatically start the priming process.
Electronic Control Module (ECM) The ECM is continually monitoring various engine conditions (engine temperature, engine detonation control , engine throttle opening and climate conditions (induction air temperature, barometric pressure and altitude level) needed to calculate fuel delivery (pulse width length) of injectors.
2002 and Up 2.5L/3.0L Ignition System Description Notes _______________________ When the ignition key switch is turned to the ”RUN” position, battery voltage is applied to both the Electronic Control Module (ECM) through the purple wire and the main power relay through the red/purple wire. As the ECM receives the ”RUN” signal, it internally completes the ground circuit of the main relay, for a short period of time, energizing the fuel pump for start– up.
Notes _______________________ _______________________ Ignition Coil Each module contains an ignition coil and amplifier circuitry which produces approximately 50,000 volts at the spark plugs.
Electronic Control Module Notes The ECM requires 8 VDC minimum to operate. If the ECM should fail, the engine will stop running. _______________________ _______________________ The inputs to the ECM can be monitored and tested by the Digital Diagnostic Terminal 91-823686A2 using adaptor harness 84-822560A5.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Flywheel Flywheel has 54 teeth under the flywheel ring gear which the crank position sensor uses to provide engine rpm and crankshaft position information to the ECM. Crank Position Sensor Monitors 54 teeth on flywheel thus determining crankshaft position and sends crankshaft position angle and engine speed signals to ECM.
Throttle Position Sensor (TPS) The TPS transmits throttle angle information to the ECM which varies the injector pulse width accordingly. Should the sensor fail, the warning horn will sound. RPM will be reduced by the ECM. TPS settings are not adjustable. TPS settings can be monitored with the Digital Diagnostic Terminal through the ECM. Voltage change should be smooth from idle to wide open throttle. If voltage change is erratic, TPS is defective.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ DDT TEST The TPS settings are not adjustable, but can be monitored with the Digital Diagnostic Terminal (DDT). Voltage change should be smooth from idle to wide open throttle. If voltage change is erratic, the TPS is defective. 1. Set the DDT’s data monitor to read TPS voltage.
VISUAL INSPECTION Notes If the DDT determines that the TPS sensor has failed, follow this procedure to determine cause: 1. Disconnect the sensor from the harness connection. 2. Visually inspect the pins at the sensor and the wires coming from the connector. Look for broken, bent, or corroded pins at the sensor and loose, broken, or corroded wires at the connector. Replace components as necessary. 3. Check the throttle cable adjustment.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ SENSOR PRESSURE TEST IMPORTANT: When testing TPS voltage, do not move the drive mechanism (rotor/wiper). 1. Connect the DDT and rotate the key to the ON position. 2. Set the DDT to read TPS voltage; expand the screen to show Now/Min/Max. NOTE: Test accuracy is improved when the TPS is at its lowest voltage reading (engine at idle).
Cylinder Head Temperature Sensor Two (2) temperature sensors are used to provide temperature information to the ECM. One sensor is mounted in each cylinder head. The ECM uses this information to increase injector pulse width for cold starts and to retard timing in the event of an over-heat condition. Should a temperature sensor fail, the ECM will default to a temperature value of 32 °F (0 °C).
Notes _______________________ _______________________ _______________________ _______________________ Air Temperature Sensor The air temperature sensor is mounted on top of the air plenum. The ECM regulates fuel flow, in part, based on manifold air temperature. As air temperature increases, the ECM decreases fuel flow. Should the air temperature sensor fail, the ECM will default to a temperature value of 32 °F (0 °C).
Manifold Absolute Pressure (MAP) Sensor The MAP sensor is located on top of the air plenum. The ECM regulates fuel flow, in part, based on manifold absolute pressure. The MAP sensor becomes more critical in engine running quality as the engine is operated at higher altitudes (i.e. mountain lakes). Should the MAP sensor fail, the ECM will default to a value of approximately 14.7 psi. The MAP sensor’s DDT readout will vary according to altitude, throttle plate opening and barometric pressure.
Notes _______________________ _______________________ DDT TEST IMPORTANT: A fouled or faulty MAP sensor displays a default value of approximately 14.7 psi. _______________________ 1. With the DDT connected, start the engine. _______________________ 2. Quickly open the throttle and close it again while observing the MAP sensor readings on the Data Monitor function of the DDT.
5. The voltmeter should read +5 volts, if not, connect the voltmeter across the PPL/YEL wire and the engine ground. If the voltmeter indicates +5 volts, there is an open in the ground circuit (BLK/ORN). Notes _______________________ _______________________ NOTE: All the ground wires for the sensors are spliced together and connect to the PCM at (Pin 22 of A connector).
RESISTANCE TEST 1. Disconnect the sensor from the harness connection. 2. Visually inspect the pins at the sensor and the wires coming from the connector. Look for broken, bent, or corroded pins at the sensor and loose, broken, or corroded wires at the connector. Replace components as necessary. 3. Perform a resistance test. If the sensor fails this test, replace the sensor.
EFI Detonation Control System The detonation control circuit is located in the ECM. This circuit monitors 2 detonation (knock) sensors; 1 each located in each cylinder head. When detonation is initially detected, timing is retarded. If detonation continues, fuel mixture is richened.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Main Power Relay Typically, the starter draws 210 amps when cranking the engine, lowering the voltage available from the battery.
Water Sensing System Notes The system consists of a water separating fuel filter (port side powerhead) and a sensing probe (bottom of filter). Water Sensing System Function 1) The filter separates the accumulated water from the fuel. _______________________ _______________________ _______________________ _______________________ 2) A voltage is always present at sensing probe. When water reaches top of probe it complete the circuit to ground.
Notes Component Description and Diagnostics _______________________ The Propulsion Control Module (PCM) is dependable and should not be replaced before testing the suspected sensor or wiring harness. The corrosive environment of marine applications combined with vibration suggests that most problems occur with either the wiring or the sensor.
Charging System Alternator Notes Battery charging system is contained within the belt driven alternator, including the regulator. At cranking speeds, electrical power for the engine is provided by the boat battery – mini-mum recommended size is 490 Cold Cranking Amperes (CCA) or 630 Marine Cranking Amperes (MCA). Above 550 RPM, all electrical power is provided by the alternator.
2002 Warning System Signals NOTE: The warning system signals which includes audible and visual indicator involving the horn and gauges will identify the potential problems listed in the chart.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Guardian Protection System The guardian protection system monitors critical engine functions and will reduce engine power accordingly in an attempt to keep the engine running within safe operating parameters.
Guardian System Activation Function Cooling System Problem Warning Horn Sound Description Continuous Engine Guardian System is activated. Power limit will very with level of overheat. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole. If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check water intake holes for obstruction.
Smartcraft Data Worksheet Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number: Date: DDT Software Version: Data Monitor – Two Stroke EFI ENGINE # ENGINE RPM IDLE 1500 RPM 3000 RPM TPI 1 VOLT BATTERY VOLTS PWR 1 VOLTS COOL TMP STB F COOL TMP PRT F MAP PSI AIR TMP F BLOCK PSI OIL INJ CNT TPI % AIR COM TMP F OIL LEVEL FUEL LEVEL AVAILABLE PWR % SHIFT TRIM PITOT PADDLE WHEEL LAKE/SEA TMP F SPARK ANG BTDC FPC TOTAL OZ 90-898303 4-38 NOTES
Smartcraft Data Worksheet - 90-881929--1 Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number: Date: DDT Software Version: Fault Seconds Engine #1 Engine #2 BATT VOLT HIGH Run History RUN TIME HR BATT VOLT LOW RPM 0-749 BLOCK PRESS LOW 750-1499 COMP OVERHEAT 1500-2999 ETC MOTOR OPEN 3000-3999 ETC MOTOR SHORT 4000-4499 FUEL P INPUT HI 4500-4999 FUEL P INPUT LO 5000-5499 GUARDIAN 5500-6249 KNOCK SENS1 6250+ KNOCK SENS2 BREAK-IN LEFT OIL PSI STR
SmartCraft Data Worksheet Dealer Name: Engine S/N: FREEZE FRAME FAULT BUFFER DATA FAULT ID Fault Buffer 0 Fault Buffer 1 Fault Buffer 2 Fault Buffer 3 Fault Buffer 4 Fault Buffer 5 Fault Buffer 6 Fault Buffer 7 Fault Buffer 8 Fault Buffer 9 BREAK-IN BARO PSI BATT VOLTS BLOCK PSI BOAT SPEED AIR TEMP F COOL TEMP F DEMAND % ENGINE RPM ENGINE STATE FPC TOTAL FREQ COUNTER FUEL LEVEL % SHIFT LAKE/SEA TEMP F LOAD % MPRLY MAP PSI OIL LEVEL % PORT TAB POS AVAILABLE PWR % RUN TIME STAR TAB POS TPS % TRIM
SmartCraft Data Worksheet Fault ID Description _______________________ BREAK-IN _______________________ • _______________________ Engine is still within oil break-in clock BARO PSI • _______________________ The barometric pressure when the fault occurred BATT VOLTS • Notes The battery voltage when the fault occurred _______________________ _______________________ BLOCK PSI _______________________ • _______________________ The engine block pressure when the fault occurred BOAT SPEED • ___
Notes _______________________ MPRLY • _______________________ _______________________ _______________________ A value of zero indicates there was no request made to activate the main power relay. A value greater than zero indicates that the main power relay was active.
SmartCraft Overview Notes SmartCraft is Mercury’s approach to vessel system integration based on a “Platform” technology. Platform technology first pioneered by the automotive industry, enables automobile manufacturers to link and share electronic information between propulsion, chassis, and automobile body electrical systems.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 4) As the SmartCraft system evolves one can envision automated trim tabs controlling vessel pitch, roll, and yaw.
SmartCraft System Rules 1) 2) 3) 4) 5) Each system must contain exactly two (2) terminators. Terminators should be located at the furthest ends of the main CAN bus. The total CAN bus should not exceed 130 ft (39.6 meters) Each CAN Bus must only be powered from one engine. All unused junction ports must be capped using weather caps.
Notes _______________________ SmartCraft System Typical Layout (Cont.
System Monitor System Monitor Legend 90-898303 4-47
Section 5 - Product Changes 90-898303 5-1
Table of Contents Table of Contents ............................................................................................. 2 Model Year Changes ........................................................................................ 4 ECM/PCM .................................................................................................... 4 Throttle Roller .............................................................................................. 4 Cylinder Head Location Pins - 3.
Notes _______________________ Model Year Changes _______________________ ECM/PCM _______________________ 2004 MY _______________________ • Improved reference voltage circuit for SmartCraft sensors _______________________ • Higher tolerance to under cowl heat (105° C).
Cylinder Head Location Pins - 3.0 Litre Models Notes _______________________ 2004 MY Cylinder heads will have location pins between the head and the cylinder block deck surface. Product improvement, increases bore seal life and durability, reducing bore seal leakage. _______________________ _______________________ _______________________ Piston Pin Material Change - 3.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ New Model - 200 HP 3.0 Litre 2004 MY This new model 200 HP, 3.0 Liter EFI will replace the 200 HP, 2.5 Liter EFI. This engine will use the 3.0 Liter work EFI cylinder block with the 225 EFI heads, and a new ECM calibration.
Returnable Engine Carton Notes _______________________ 2004 RUNNING CHANGE Starting with the 2004 model year Mercury will start shipping some outboards in steel frame returnable engine cartons. Rigid container, lower shipping damage, has 3-way fork entry, easy to pack, easy to unpack, ability to ship and store outdoors, minimal disposal. The engine is bolted to the steel frame and the frame is covered with a vinyl cover.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Steel frame returnable engine carton in up right position.
Trim Tab Removed - 2.
Notes Shift Link 3.
Starter Motor – 2.5 and 3.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 2005/2006 Model Year Changes14 Pin Adapter and Control Harnesses Models Affected 4-stroke models 9.
Adapter Harness Notes 84-896542T_ Adapts 2006 model year and newer engines that use the 14 pin harness to the old round 8 pin control or key/choke harness. Use with engines not being equipped with SmartCraft gauges.
Notes Analog Instrument Harness _______________________ _______________________ 84-892990T01 connects to the 10 pin/J-box connection on new 14 pin key/choke harness, to operate analog gauges _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ New Test Key Switch 14 pin15000A12 Service tool to isolate the boat from the engine.
Notes New Decal Design • • _______________________ All engines will be salt water version Stainless steel parts added to 20 inch versions _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Power Trim Rams _______________________ _______________________ • • • Ball at end of trim rams will be
Notes Dielectric Grease _______________________ _______________________ _______________________ • • Dielectric grease will no longer be used on electrical connection except the 8 pin cannon plug on 2005 product Improved electrical connection allows the removal of the grease _______________________ _______________________ _______________________ _______________________ Drive Shaft Seal Carrier • • Orange coating on carrier O-ring flaking off, replaced with black O-ring.
Upper Engine Mounts Notes _______________________ • • • 3.
Gear Case Mounting Nuts Notes _______________________ _______________________ _______________________ • • • • 3.0 Liter EFI 2006 MY The current nickel plated brass nut can crack due to corrosion Changing to a stainless steel nut. The change will occur about model year switch over New nut 11-896895 will back fit.
Section 6 - Tools 90-898303 6-1
Table of Contents Table of Contents ............................................................................................. 2 Special Tools .................................................................................................... 3 Digital Diagnostic Terminal - P/N 91-823686A2 .......................................... 3 Injector Test Harness - P/N 91-833169A1 ................................................... 3 CDM Test Harness - P/N 84-825207A1............................................
Special Tools Notes Digital Diagnostic Terminal - P/N 91-823686A2 Refer to the Digital Diagnostic Terminal Order Form for all cartridge and adapter harness part numbers. _______________________ _______________________ _______________________ Injector Test Harness - P/N 91-833169A1 _______________________ For 2.4L, 2.5L, and 3.0L EFI.
Notes _______________________ _______________________ CDM Test Harness - P/N 84-825207A1 Early Style (Mercury) CDM, 3 pin. TPI Test/Adjust Harnesses for 1995– 2001 3.0L EFI and carb engines. _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ CDM Test Harness - P/N 84-825207A2 _______________________ Later Style (Echlin) CDM, 4 pin.
DDT Carrying Case P/N 804805 Notes _______________________ Service Tachometer DMT 2000 - P/N 91-854009A3 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Service Tachometer DMT 2004 - P/N 91-892647A01 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ ___________________
Notes Multi-Meter DVA Tester - P/N 91-99750A1 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ NOTE: There are 3 different Multi-Meter DVA Testers using the part number 91-99750 or 91-99750A1 having a DVA built in.
Remote Starter Switch - P/N 91-52024A1 Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Single Fuel/Air Pressure 160 PSI Gauge - P/N 91-16850A7 _______________________ NOTE: To convert 100 psi gauge P/N 91-16850A1 to 160 psi gauge, order upgrade 91-16850--1.
