Ignition System

Electrical System
Section 4B - Ignition System
Table of Contents
Spark Plug Specifications.................................................. 4B-2 Spark Plug.................................................................. 4B-3
Finding Other Diagrams.....................................................4B-2 Spark Plug Wire—High‑Tension Leads...................... 4B-4
Ignition System Components............................................. 4B-2 Ignition Coil................................................................. 4B-6
EFI System Maintenance Precautions........................4B-2

4
B

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Ignition System

Special Tools
DMT 2004 Digital Multimeter 91‑892647A01

Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

V Hz
H z TEMP
mA
A
voltages; records maximums and minimums simultaneously, and accurately
reads in high RFI environments.
mV IG
OFF IP

TEMP

A mA COM V Hz

4516

Computer Diagnostic System (CDS) Order through SPX

Monitors all electrical systems for proper function, diagnostics, and calibration
purposes. For additional information, pricing, or to order the Computer
Diagnostic System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA ‑ 1‑800‑345‑2233
4520 Canada ‑ 800‑345‑2233
Europe ‑ 49 6182 959 149
Australia ‑ (03) 9544‑6222

Spark Plug Specifications

IMPORTANT: All of the spark plugs installed in the engine must be of the same type.
IMPORTANT: Servicing dealers should refer to the latest spark plug listing for acceptable spark plugs.

Description Specification
Firing order 1‑8‑7‑2‑6‑5‑4‑3
Spark plug type AC Platinum (AC 41‑983)
Spark plug gap 1.52 mm (0.060 in.)

Finding Other Diagrams

NOTICE
Refer to the appropriate Mercury MerCruiser Diagram Binder for wiring diagrams or other diagrams not found in this manual.

Ignition System Components

EFI System Maintenance Precautions
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

IMPORTANT: Refer to the following precautions when working on or around the electrical harness, or when adding other
electrical accessories, to avoid damage to the electrical system.
• Do not tap accessories into the engine harness.
• Do not puncture wires for testing (probing).
• Do not reverse the battery leads.
• Do not splice wires into the harness.
• Do not attempt diagnostics without the proper, approved service tools.

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 Ignition System

Spark Plug
Checking
1. Disconnect the spark plug wires (high‑tension leads) from the spark plugs.

a Non-ECT engine model shown, ECT models similar

a - Coil pack
b - Spark plug wires at spark plugs

b 49560

NOTE: Use care when removing the spark plug wires from the spark plugs. Twist the boot 1/2 turn before removing. Firmly
grasp and pull on the boot to remove the wire from the spark plug.
2. Remove the spark plugs.
3. Ensure that all of the spark plugs are from the same manufacturer and have the same spark plug number.
4. Inspect each spark plug gap, adjust as necessary to maintain proper specifications.
5. Inspect each spark plug individually for badly worn electrodes and glazed, broken, or blistered porcelain. Note the cylinder
location of any damaged spark plug for future reference.
6. If a damaged spark plug is found, replace all of the spark plugs in the engine.
NOTE: Cracks often occur at the base of the insulator.

a- Porcelain insulator
b- Insulator base
a c- Shell
d- Proper gap
e- Side electrode
b f- Center electrode
c
f d

e 19728

7. Clean the plug seating area on the cylinder heads and spark plugs.
8. Reinstall and torque the spark plugs that pass inspection. If any spark plug requires replacement, replace all of the spark
plugs.

Description Nm lb. in. lb. ft.

spark plugs 20 – 15
9. Connect the spark plug wires (high‑tension leads) onto the spark plugs.

Replacing
1. Clean the plug seating area on the cylinder heads and spark plugs.
IMPORTANT: When adjusting gap, do not bend the center electrode.

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Ignition System

2. Adjust the spark plug gap with a round feeler gauge. Bend the side electrode to adjust the gap.

a - Seating area
b - Gap

a
b 19729

IMPORTANT: Spark plugs should be torqued to the amount specified. If they cannot be torqued, the spark plugs should be
hand tightened until the plug contacts the cylinder head. Then, using an appropriate wrench and socket, slightly rotate
(approximately 1/8 or less of a full turn) to create a seal and secure the spark plug.
3. Install the spark plugs and torque to specifications.

Description Nm lb. in. lb. ft.

New spark plug 30 – 22
4. Install the spark plug wires in the proper order.

Spark Plug Wire—High‑Tension Leads

Checking
1. Inspect the spark plug wires for damage, such as being cracked, cut, or oil soaked.
2. Inspect the spark plug boots for damage.
3. Check the spark plug wires for continuity using a multi‑meter, digital/volt/ohm meter.

Spark plug wires (high tension lead)

Maximum ohms per 25.4 mm (1 in.) 1000

DMT 2004 Digital Multimeter 91‑892647A01

Computer Diagnostic System (CDS) Order through SPX
4. Replace any spark plug wires that do not meet specifications.
5. if any damaged spark plug wires are found, replace all of the spark plug wires.

Replacing
IMPORTANT: Only use spark plug wires recommended for marine application.
NOTE: Replace one spark plug wire at a time to reduce the risk of installation error.
1. Disconnect individual spark plug wire from the spark plug.

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 Ignition System

NOTE: Use care when removing the spark plug wires from the spark plugs. Twist the boot 1/2 turn before removing. Firmly
grasp and pull on the boot to remove the spark plug wire from the spark plug.

a ECT engine model shown, non-ECT

models similar
a - Coil packs (2)
b - Spark plug wires to coil (8)
c - Starboard spark plug wires to spark
plugs (4)

c 49559

2. Remove the Spark plug wire retainer bracket.

a - Spark plug retainer bracket

b - Screw (2)
c - Spark plug wire (8)

49564
a c
b c
3. Pull the spark plugs wire from the coil.
4. Install the new spark plug wires in the proper order.
IMPORTANT: Spark plug wire routing must be kept intact during service and followed exactly when spark plug wires have
been disconnected or when spark plug wire replacement is necessary. Failure to route the spark plug wires properly can
lead to radio frequency interference, cross firing of the plugs, and shorting of leads to ground.

90-879172243 DECEMBER 2011 Page 4B-5

Ignition System

a. Position the spark plug wires in the spark plug wire supports and retainers.

1
3
5 7 8
6
4 2

a b c d e f 49562

Engine parts removed for visual clarity

a - Retainer clip on spark plug wires number 1 and 3
b - Retainer clip on spark plug wires number 3 and 5
c - Retainer clip on spark plug wires number 5 and 7
d - Retainer clip on spark plug wires number 6 and 8
e - Retainer clip on spark plug wires number 4 and 6
f - Retainer clip on spark plug wires number 2 and 4

b. Attach the spark plug wires to the appropriate spark plug and coil pack. Each end must fit securely.
c. Install the spark plug retainer bracket and mounting screws.
d. Tighten the bracket mounting screws to specification.

a- Cylinder numbers on coil (8)

b- Cylinder numbers on spark plug wire (8)
a c- Screw
d- Spark plug wire retainer bracket

49563
d c

Description Nm lb. in. lb. ft.

Spark plug wire retainer bracket screw 11 96 –

Ignition Coil
NOTE: For ignition coil troubleshooting refer to the appropriate Mercury MerCruiser PCM Diagnostic Service Manual.
Removal

! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

1. Disconnect both battery cables from the battery.

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 Ignition System

2. Remove and retain the two screws securing the spark plug wire retainer bracket and remove the bracket.
3. Disconnect the spark plug wires at the ignition coils.
4. Disconnect the ignition coil harness connector.
5. Remove and retain the three ignition coil mounting screws.
6. Remove the ignition coil.

a a- Ignition coil harness connector (starboard and port)

b- Retainer bracket screw (2)
c- Ignition coil mounting screw (3)
d- Spark plug wire (8)

c
c

d
d

49796
b
Installation
1. Position the ignition coil packs onto the mounting bracket.
2. Install the ignition coil mounting screws and J‑clip. Tighten the screws to specification.

Description Nm lb. in. lb. ft.

Ignition coil screw 11 96 –
3. Connect the starboard and port ignition coil harness.
4. Connect the spark plug wires to the ignition coils.
5. Install the spark plug wire retainer bracket.
6. Install the retainer bracket mounting screws. Tighten the screws to specification.

a a- Ignition coil harness connector (starboard and port)

b- Retainer bracket screw (2)
c- Ignition coil mounting screw (3)
d- Spark plug wire (8)

c
c

d
d

49796
b

Description Nm lb. in. lb. ft.

Spark plug wire retainer bracket screw 11 96 –
7. Connect the battery cables to the battery in the following order:
a. Connect the positive (+) battery cable to the positive (+) battery terminal and tighten the cable clamp.

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Ignition System

b. Connect the negative (–) battery cable to the negative (–) battery terminal and tighten the clamp.

19726

Typical

Page 4B-8 90-879172243 DECEMBER 2011