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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines

FUEL PUMP RELAY

Pin Description

Color

Connector

Pin

30 12V Power/B+

Red

Relay #86

85 Trigger from ECM

Dark Green/Black J1-6

86 Inj./ECM 10A fuse

Black

J2-19

87 Fuel pump trigger ON

Gray Pin A

Pin A

87A N/A

N/A

MEFI4 PIN CONFIGURATION

J2 CONNECTOR

J2 Pin

Description

Color

Connector pin

Connector Type

J2-1 Battery feed

Orange

J2-2 5 Volt reference

Gray

TPS-A/MAP-C 3 Way

J2-3 Sensor ground

Black

TPS-B/MAP-A (2) 2 Way/(3) 3 Way

J2-4 Fuel PSI signal

ECT-A/IAT-B

J2-5 Emergency Stop

J2-6 Empty

J2-7 ECT coolant sensor signal

Yellow

Pin B

3 Way/Coolant

J2-8 MAP sensor signal

Light Green

Pin B

3 Way

J2-9 Empty

J2-10 Serial data

Orange

Pin G

10 Way/DLC

J2-11 Empty

J2-12 Empty

J2-13 Empty

J2-14 Empty

J2-15 Ignition bypass

Tan/Black

Pin B

4 Way/Distributor

J2-16 Distributor Reference "high" Purple/White

Pin C

4 Way/Distributor

J2-17 Empty

J2-18 Empty

J2-19 Ignition feed

Pink

#30,#86

Ignition/Inj Relay

J2-20 Oil PSI switch

Blue/White

J2-21 IAT sensor signal

Tan

Pin A

2 Way

J2-22 Empty

J2-23 TPS sensor signal

Blue

Pin C

3 Way

J2-24 Empty

J2-25 Empty

J2-26 Empty

J2-27 Empty

J2-28 Empty

J2-29 Empty

J2-30 Empty

J2-31 Ignition control

White

Pin D

4 Way

J2-32 Empty

454/502 MagnumTBI_A1R9

Содержание 454 Magnum MPI Tournament Ski

Страница 1: ...e Charger Installations Instructions for Mercury 454 502 Magnum Engines Whipple Superchargers 93 01 454 502 Magnum Installation Instructions Version A1R9 Last Updated April 1st 2010 454 502 MagnumTBI_...

Страница 2: ...Superchargers has provided a stainless restrictor for the thermostat housing that will restrict the flow like a thermostat but pressure still must be checked as this may be too much restriction ideall...

Страница 3: ...roduct as it is received by the purchaser to determine the compatibility of the product with the vessel or the device the purchaser intends to install the product on Whipple Supercharger assumes no re...

Страница 4: ...NUE USE IMMEDIATELY 3 DO NOT OPERATE ENGINE IN BOOST IF THE FUEL PRESSRUE IS BELOW THE PRESSURE SPECIFIED BY WHIPPLE INDUSTRIES 4 NEVER CHANGE THE WHIPPLE COMPUTER CALIBRATION PROGRAM ENGINE RUN FUEL...

Страница 5: ...p The engine should idle at approx 800rpm 75 and 725rpm 100 The ECU will modify both spark timing and the IAC position counts These numbers will constantly vary to maintain a smooth idle in and out of...

Страница 6: ...ure is lower another water pickup must be installed Consult with Whipple Industries for recommendations The Whipple intercooler will take water away from the engine if the water is teed from the stock...

Страница 7: ...ation guide you will see the following symbols used NOTE Used to indicate tips and information to aid in installation maintenance or use of the supercharger CAUTION Used to indicate precautions that m...

Страница 8: ...CAUSE SEVERE ENGINE FAILURE STEP BY STEP INSTALLATION INSTRUCTIONS 1 Disconnect the battery power by selecting the disconnect mode on the battery switch or removing the ground cable from all batterie...

Страница 9: ...ly forward or scribe a mark on the distributor housing marking the position of the rotor Remove MerCruiser fuel lines from stock fuel filter assembly leave your factory line routed to filter from tank...

Страница 10: ...and drill a hole using a drill or hole saw Apply marine type silicone to exposed wood and fiberglass as well as the back of thru hull fittings While holding thru hull fitting do not let it rotate on...

Страница 11: ...the water passages NOTE Apply a thick bead in the valley of the block both front and rear This should be a minimum of 3 8 ID tall See figure Install intake manifold using the 8 3 8 x 1 50 and 4 3 8 x...

Страница 12: ...ting area It s too long to install afterwards Install all other intercooler mounting bolts hand tight and then slide the compressor assembly forward Now torque the 8 3 8 intercooler mounting bolts to...

Страница 13: ...should be facing up starboard side SERP Install stainless water cross over with new gaskets figure 1 this requires you to install the new billet belt system at the same time Use the 4 aluminum spacer...

Страница 14: ...s This will allow proper cooling of the fuel You will then route the inlet from the tank to the inlet of the fuel filter then you will return all fuel to the tank If your boat does not have an open po...

Страница 15: ...nline filters All restrictions must be removed to allow proper fuel flow Remove factory fuel lines and fittings from stock fuel filter Install supplied NPT brass Tee to the stock fuel filter IN Apply...

Страница 16: ...gh pressure fuel lines You may order crimped 3 8 USCG approved fuel lines from Whipple for a minimal charge You must supply Whipple with line length and type of fitting 90 or straight only Manufacture...

Страница 17: ...oper locations Find a secure location to mount hi flow electric fuel pump Note that this pumps vibrates and can cause a harmonic noise if not mounted securely Install rubber strips on fuel pump clamps...

Страница 18: ...ilter IN 2 Locate the barbed fitting on starboard side of intake manifold 5 32 Install supplied 5 32 vacuum hose and route to fuel pressure regulator barbed port Secure with zip ties Avoid tight bends...

Страница 19: ...preferably near the starter Secure with 20 hose clamps VBELT Utilize factory hose from factory coolers Utilize the supplied U bend hose and couple to the factory hose Use the supplied intercooler tee...

Страница 20: ...97 engines will receive PCV valve to install into port side valve cover Route 3 8 hose to barbed fitting coming from throttle body Install new 3 8 ID hose with new 90 degree plastic fitting onto PCV...

Страница 21: ...pplied 5 32 vacuum hose and route to fuel pressure regulator barbed port Secure with zip ties 25 Fill supercharger with oil to middle of knurled area on dipstick 5W 50 synthetic engine oil DO NOT OVER...

Страница 22: ...d by a black wire Cut the blue green and pink wires that you traced leaving approx a few inches for a proper wiring connection Utilize the supplied weather style butt connectors or solder wires to the...

Страница 23: ...sensor to sensor in manifold Find the factory map sensor connector and plug in the wiring extension Now install the new orange map sensor connector to the map sensor located on the front plate See fi...

Страница 24: ...ound Black E Battery Power Red F Factory Turn ON Wire Gray RELAY PIN LAYOUT Electric Fuel Pump 27 Install SC belt by releasing the tension from the tensioner and loosening the mounting bolt on the sli...

Страница 25: ...throttle assembly Verify that the linkage does not go over center at any time Should be able to go back and forth 100 without binding BEFORE STARTING THE ENGINE MAKE SURE THE THROTTLE CABLE OPERATION...

Страница 26: ...re paper clip to hold the engine in base timing mode Manually adjust throttle so engine RPM is steady 1500rpm If you have a Rinda scan tool set the engine in service mode which will set it in base tim...

Страница 27: ...idle speed that the motor is always going to try to achieve The rpm idle speed should be 750 rpm once motor is up in the 80 range of engine coolant temperature On the starboard side of throttle body...

Страница 28: ...the motor should not hunt more than 100 RPM Rev engine up past 2500 rpm and bring back at a rapid rate The motor should not die it should come back to the desired idle speed within 1 5 seconds If it d...

Страница 29: ...er to observe the gauge Perform the test in a safe area If it does not maintain fuel pressure you must find the restriction as this results in a lean air to fuel condition MAINTENANCE AND SERVICE It i...

Страница 30: ...ensor use the other pipe holes located in the manifold 8 Do not design your own fuel system the system is designed for use and installation as we specify 9 Do not run more timing than 8 degrees base 1...

Страница 31: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 31...

Страница 32: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 32...

Страница 33: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 33...

Страница 34: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 34...

Страница 35: ...14 Tachometer output Gray Engine harness gray J1 15 Idle air control B low Green Black Pin A 4 Way IAC J1 16 Idle air control A high Blue White Pin D 4 Way IAC J1 17 Knock signal 1 Blue Knock Sensor S...

Страница 36: ...T B J2 5 Emergency Stop J2 6 Empty J2 7 ECT coolant sensor signal Yellow Pin B 3 Way Coolant J2 8 MAP sensor signal Light Green Pin B 3 Way J2 9 Empty J2 10 Serial data Orange Pin G 10 Way DLC J2 11 E...

Страница 37: ...r reference HIGH Oil PSI switch Throttle position sensor signal Ignition control J2 MEFI 4 Inlet air temp sensor signal IAC B LOW IAC A HIGH IAC A LOW IAC B HIGH A D C B Ground 5V reference MAP signal...

Страница 38: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 38...

Страница 39: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 39...

Страница 40: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 40...

Страница 41: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 41...

Страница 42: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 42...

Страница 43: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 43...

Страница 44: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 44...

Страница 45: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 45...

Страница 46: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 46...

Страница 47: ...Whipple Charger Installations Instructions for Mercury 454 502 Magnum Engines 454 502 MagnumTBI_A1R9 47...

Страница 48: ...uctions for Mercury 454 502 Magnum Engines 2 BAR MAP SENSOR SCALE 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Manifold PSI KPA Senso...

Страница 49: ...f road use are considered racing parts and carry no warranty either expressed or implied as we have no control over how they are used On warranty items repair replacements will be limited to parts man...

Страница 50: ...s install as shown in diagram For engine water pickups you want your trailing edge to only hang between 325 625 When running separate water pickups the fuel cooler must be in the factory water loop an...

Страница 51: ...hull fitting Intercooler out Intercooler in Fuel cooler Oil cooler Sea pump Engine block Exhaust inlet Exhaust inlet Power steering cooler Transom pickup Thru hull fitting Manifold bleed drain 1 4 li...

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