Electrical: Section 2A - Ignition
Electrical: Section 2A - Ignition
Electrical: Section 2A - Ignition
ELECTRICAL
Section 2A – Ignition
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Direct Injectors . . . . . . . . . . . . . . . . . . . . . . . 2A-24
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 2A-24 A
Electrical Components Model Year 2000 . . . 2A-4 Disconnecting Harness Connectors from
Electrical Components . . . . . . . . . . . . . . . . . . . . . 2A-6 Ignition Coils and/or Injectors . . . . . . . . . . 2A-25
Coil Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Shift Interrupt Switch . . . . . . . . . . . . . . . . . . 2A-25
Solenoid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-26
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-13 Troubleshooting Without Digital
Ignition Component Description . . . . . . . . . . . 2A-14 Diagnostic Terminal . . . . . . . . . . . . . . . . . . . . . . 2A-26
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14 Troubleshooting with the Digital
Electronic Control Module (ECM) . . . . . . . 2A-15 Diagnostic Terminal . . . . . . . . . . . . . . . . . . . . . . 2A-27
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-28
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 DDT Functions – Version 4.0 and 4.1 . . . . . . 2A-29
Coil Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-17 DDT Functions – Version 1.0 . . . . . . . . . . . . . 2A-30
Crank Position Sensor . . . . . . . . . . . . . . . . 2A-18 DFI Troubleshooting Guide . . . . . . . . . . . . . . . 2A-31
Throttle Position Sensor (TPS) . . . . . . . . . 2A-18 Ignition Components Removal and
Throttle Position Sensor (TPS) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-19 Flywheel Cover . . . . . . . . . . . . . . . . . . . . . . 2A-35
Charging System Alternator . . . . . . . . . . . . 2A-20 Electronic Control Module (ECM) . . . . . . . . 2A-36
Temperature Sensor . . . . . . . . . . . . . . . . . . 2A-21 Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . 2A-37
Manifold Absolute Pressure Crank Position Sensor . . . . . . . . . . . . . . . . . 2A-38
(MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . 2A-23 Throttle Position Sensor (TPS) . . . . . . . . . . 2A-39
Air Temperature Sensor . . . . . . . . . . . . . . . 2A-23
Specifications
IGNITION Type Digital Inductive
SYSTEM Firing Order 1-2-3-4-5-6
Model Year 2000
Spark Plug Type CHAMPION QC12GMC
Spark Plug Gap 0.040 in. (1.0 mm)
Model Year 2001
Spark Plug Type NGK PZFR5F-11 (heavy duty)
Spark Plug Gap 0.043 in. (1.1 mm)
Maximum Timing Not Adjustable; Controlled by ECM
Idle Timing Not Adjustable; Controlled by ECM
Throttle Position Sensor
Model Year 2000
@ Idle 4.0 - 4.7 vdc
@ W.O.T 0.4 - 1.3 vdc
Model Year 2001
@ Idle 0.4 - 1.3 vdc
@ W.O.T 4.0 - 4.7 vdc
Crank Position Sensor
Air Gap 0.025 in. – 0.040 in.
(0.635 mm – 1.01 mm)
Special Tools
1. Digital Diagnostic Terminal (DDT) 91-823686A2
55117
4 16 62 49
5 67
66
65
46 52
55 50
53
43
51 48
57 64
44 61 58
59 47
56 62 54
70 63 31
30
29
32
69
68 27
28
42
26
*NOTE: Coat all eyelet wiring terminals with #25 GACO N700.
*NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with #6DC-4.
Electrical Components
37 36
12 10
10 11 34
9 35 A = TO BLOCK
8 A
7 33 18
45
39
25
19
6 38
17 2324
22
40 21
38 20
1
2 TO
3 13 BLOCK
14 15 41
4 16 60 49
5 67
66
65
46 52
52 50
53
43 48
51
57 64
44 61 58 59 47
56 62 54
70 63 31
30
29
32
69
68 27
28
42
26
NOTE: COAT ALL EYELET WIRING TERMINALS WITH #25 GACO N700
NOTE: COAT ALL MULTI-PIN ELECTRICAL CONNECTIONS (EXCEPT POWER TRIM RELAY CONNEC-
TORS) WITH #6 DC-4
A = TO BLOCK
Electrical Components
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
41 1 ELECTRICAL PLATE ASSY
42 1 ENGINE HARNESS
43 5 FUSE
44 1 FUSE COVER
45 1 BRACKET
46 1 RELAY PLATE ASSEMBLY
47 1 RELAY PLATE
48 3 SCREW (M6 x 12) 100 11.5
49 1 BATTERY CABLE (NEGATIVE)
50 2 SCREW (M6 x 14) 35 4
51 1 STARTER SOLENOID
52 2 GROMMET
53 2 SCREW (M6 x 25) 35 4
54 1 CABLE (BLACK)
55 2 BUSHING
56 1 BATTERY CABLE (POSITIVE)
57 2 LOCKWASHER
58 2 NUT (5/16-18) 50 5.5
59 2 NUT (10-32) 8 0.9
60 1 SCREW (M8 x 20) 18 24.5
61 1 BOOT (RED)
62 1 CAP NUT
63 1 CABLE
64 2 INSULATOR BOOT (YELLOW)
65 1 CLIP
66 1 SCREW (M6 x 14)
67 1 CLIP
68 1 STA STRAP
69 1 NUT
70 1 PLUG (GRAY WIRE) (DIGITAL)
18
1
11
13 12
22
14
10 9
8
10
80
21
80
2
11
12 2
22
13 7
14 80
10 9
4 80
6
14 12 34
10 9
15 4 TO
6 BLOCK
46
45
13 17
34
16 2
9 24 27
11
25
10 23
4
5
43 8 3
4
23 24 26
22
6 20
7 44
19 21
18
*NOTE: Coat all eyelet wiring terminals with #25 GACO N700.
*NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with #6DC-4.
14 12 34
10 9
15 4 TO
6 BLOCK
46
45
13 17
34
16 2
9 24 27
11
25
10 23
4
5
43 8 3
4
23 24 26
22
6 20
7 44
19 21
18
*NOTE: Coat all eyelet wiring terminals with #25 GACO N700.
*NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with #6DC-4.
Theory of Operation
When the ignition key is turned to the RUN position, battery voltage is applied to the main
relay through the PURPLE wire. When the Electronic Control Module (ECM) receives a
signal from the Crank Position Sensor, the main relay ground circuit is completed through
the ECM. The main relay is then closed and D.C. current from the battery or charging sys-
tem is transferred through the main relay 20 ampere fuse to the positive terminal of all 6
ignition coil primary windings. The negative terminal of the coil primary is connected to
engine ground through the ECM. When this circuit is closed, a magnetic field is allowed
to be built up in the ignition coil. The Crank Position Sensor senses the location of the 24
teeth (Model 2000) or 54 teeth (Model 2001) on the flywheel and supplies a trigger signal
to the ECM. When the ECM receives this signal, the ECM will then open the ground circuit
of the coil primary. The magnetic field in the ignition coil primary will then collapse cutting
across the coil secondary winding creating a high voltage charge (50,000 volts) that is
sent to the spark plug.
a b
Model 2000
d c
57777
57494
a b
Model 2001
d c
58459
58707
57779
Flywheel
Model Year 2000 – 24 teeth under the flywheel ring gear
Model Year 2001 – 54 teeth under the flywheel ring gear
Provide engine rpm and crankshaft position information to the ECM through the crank
position sensor.
57799
Ignition Coils
Model Year 2000/2001 – Inductive type ignition coils are used on the DFI engines.
12 volt DC is supplied to the coils at all times from the boat battery. For a predetermined
length of time (dwell), the primary circuit of the coil is completed by closing the electrical
circuit within the coil driver. When the coil driver circuit opens, the primary field of the coil
collapses inducing high voltage in the secondary windings which produces up to 50000
volts at the spark plugs.
57785 58701
Coil Driver
Model Year 2001 only
The ECM sends a 5 VDC pulse to the coil driver mounted on each ignition coil. Which coil
driver receives this pulse is determined by the ECM receiving a signal from the crank posi-
tion sensor.
When the coil driver receives its ECM pulse (signal), it closes its circuit which allows the
primary side of the ignition coil to build up energy which it initially receives from the boat
battery.
When the ECM pulse (signal) to the coil driver drops below 1.3 volts, the coil driver opens
its circuit which causes the primary field of the ignition coil to collapse. This field collapse
induces a voltage buildup in the secondary winding of the ignition coil resulting in a poten-
tial voltage of up to 50000 volts at the spark plug.
58701
a - Coil Driver c - 2 Pin Connector
b - 4 Pin Connector
Coil Driver Ohm Test
GREEN/STRIPE
GREEN/STRIPE
RED/YELLOW GREEN/STRIPE
BLACK GREEN/STRIPE
58418
57796
57797
a
a - Press on cover below electrical connection
5. Voltage reading should change:
• Less than a couple of digits (i.e. 1.90 v to 1.92 v)
*NOTE: Version 5.0 cartridge gives 3 decimal point (millivolts) accuracy if below 1 volt.
• Less than 10 millivolts (i.e. 0.293 v to 0.285 v)
Replace any TPS that fails either test.
57806
Temperature Sensor
Three (3) temperature sensors are used to provide cylinder head temperature information
to the ECM. One sensor is mounted on each cylinder head and one in the air compressor
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.
b
a a
57794
57795
MODEL 2000 PORT MODEL 2000 STARBOARD
e
c
MODEL 2001
a - Cylinder Temperature Sensor
b - Air Compressor Temperature Sensor
c - Cylinder Temperature Sensor (PORT
d - Air Compressor Temperature Sensor
e - Cylinder Temperature Sensor (STARBOARD)
57793
57793
Direct Injectors
6 direct injectors (1 per cylinder) are used to inject a fuel/air mix into cylinders. Injectors
are mounted between fuel rails and cylinder heads.
57986 57985
Fuel Injectors
6 fuel injectors (1 per cylinder) are used to provide fuel from the fuel rail to the direct injec-
tors. The fuel injectors are mounted in the fuel rail.
57785
54871
57737
a - Shift Interrupt Switch
The shift interrupt switch is designed to reduce the torque load on the gear case compo-
nents to assist in shifting. The switch is monitored by the ECM which will interrupt the fuel
flow momentarily to 3 cylinders (#1, #2 and #4) when engine speed exceeds 600 rpm in
neutral.
The switch function can be monitored by the DDT. The DDT will display ON when out-
board is in neutral and OFF when in gear.
The switch is open (no continuity) when outboard is in gear and closed (continuity) when
outboard is in neutral.
If shift operation is difficult, shift interrupt switch function can be checked by the DDT or
an ohmmeter – for open or closed operation and for a continuity check of the switch har-
ness for shorts or open wiring.
Troubleshooting
The ECM is designed such that if a sensor fails, the ECM will compensate so that the en-
gine does not go into an over-rich condition.
Disconnecting a sensor for troubleshooting purposes may have no noticeable effect.
a
c d
b
The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to
help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines.
Attach the diagnostic cable to the ECM diagnostic connector and plug in the software car-
tridge. You will be able to monitor sensors and ECM data values including status switches.
The ECM program can help diagnose intermittent engine problems. It will record the state
of the engine sensors and switches for a period of time and then can be played back to
review the recorded information.
Refer to the Digital Diagnostic Terminal Reference Manual for complete diagnostic proce-
dures.
Notes:
Ignition System:
– Check for proper operation by
using Inductive Timing Light
91-99379.
– Check battery voltage
(RED/YEL Lead) @ ignition
coils.
– Check for blown fuse (C15).
– Check battery voltage to fuse
from main power relay
(PURPLE Lead).
– Check for shorted stop wire
(BLK/YEL).
1.9A Crank Position Sensor not – Check crank position sensor
functioning setting [0.015 in. – 0.040 in.
(0.38mm – 1.01mm)] from
flywheel or for defective crank
position sensor.
– Defective ECM.
Power Supply:
Clean and inspect remote control
male and female harness connec-
tors.
2. Engine cranks, starts and 2.0 Low air pressure in rail See 1.2
stalls
2.1 Low fuel pressure in rail See 1.2 and 1.3
2.2 Abnormally high friction in Check for scuffed piston or other
engine sources of high friction.
2.3 Air in fuel system/lines See 1.3 Crank and start engine
several times to purge.
2.4 TPS malfunction Check motion of throttle arm. Stop
nuts should contact block at idle
and WOT. Check TPS set-up. Must
connect DDT with adapter harness
(84-822560A5) to ECM.
2.5 Remote control to engine Clean and inspect male and fe-
harness connection is poor male connectors.
2.6 Flywheel misaligned during Remove flywheel and inspect.
installation
9. Loss of spark on 1 cylin- 9.1 Loose wire or pin in connectors Check connectors.
der between ECM and coil primary.
9.2 Faulty ignition coil. Replace coil.
9.3 Faulty spark plug. Replace spark plug.
9.4 Faulty spark plug wire Replace spark plug wire.
Note: Due to the long spark dura-
tion of this ignition system, the
DDT may indicate the incorrect cyl-
inder as having an ignition fault.
Example: If the DDT indicates an
ignition fault on cylinder #4, the
problem may be on the prior cylin-
der in the firing order – I.E. cylinder
number #3.
57783
INSTALLATION
Install flywheel cover by inserting the front pin and air tube into the rubber grommets and
then pushing the cover down onto the rear pin and air intake tube for the air compressor.
a
b
57783
c a
57789
a - Electronic Control Module
b - Screw [Torque to 100 lb in. (11.5 Nm)]
c - Bracket
d - Screw [Torque to 70 lb in. (8.0 Nm)]
e - Bushing
f - Grommet
g - Bracket
h - Screw [Torque to 100 lb. in. (11.5 Nm)]
INSTALLATION
1. Secure ECM to powerhead with 3 bolts.
2. Install rubber pad and bracket for the fuse holder.
3. Reconnect harness connectors.
a
g b
p
f
h e
c d
i
j k
57785
k d
c
a e
l
o
c
f
q
h m
i j
58701
a - Electrical Mounting i - Spark Plug Boot
Plate j - Spark Plug
b - Screw [Torque to 35 lb. k - Bushing
in. (4.0 Nm)] l - Screw [Torque to 60 lb.
c - Washer in. (7 N m)]
d - Rubber Grommet m - Coil Driver (3)
e - Bolts (4) – Torque to n - Screw [Torque to 60 lb.
20 lb. ft. (27 N·m). in. (7 N m)]
f - Ignition Coils (6) o - Ground Strap
g - Screw [Torque to 80 lb. p - Model 2000
in. (9.0 Nm)] q - Model 2001
h - Spark Plug Lead
INSTALLATION
1. Fasten coils to electrical mounting plate as shown.
2. Reinstall electrical mounting plate.
3. Reconnect spark plug lead and coil harness.
Crank Position Sensor
REMOVAL
1. Disconnect harness.
2. Remove bolt securing sensor to bracket.
e
a
b
c
d
57796 56069
a - Screw [Torque to 50 lb. c - Bracket
in. (5.5 Nm)] d - Guide Bracket
b - Crank Position Sensor e - Screw [Torque to 100 lb. in. (11.5 Nm)]
INSTALLATION
1. Fasten sensor to bracket with bolt.
2. Set air gap @ 0.025 in. – 0.040 in. (0.635 mm – 1.01 mm)
3. Reconnect sensor harness.
d c
a f e
g
h
h i