Marine Solutions - Install Instructions

Electronic Oil Injection 1997-1999 Mercury Sport-Jet Engines Installation Instructions
Test the Oil Warning System per the applicable Mercury Service Manual and assure normal engine compression before beginning installation. Replace all defective and suspect parts, with original Mercury parts. Installation requires resistor spark plugs such as NGK BUZ8H.
	Remove oil pump
1.	Disconnect the 12V starting battery.
2.	Remove the oil lines and drain the engine reservoir tank.
3.	Remove the oil link rod from the oil pump and carburetor linkage.
4.	Remove the oil pump, bearing assembly and driven gear from the crankcase.
5.	Clean and check that the oil pump rotates freely in a counter-clockwise direction.
6.	Clean and check that the magnet plug is recessed, that the bearing is not damaged, and that the outside diameter of the bearing is under.626 inch to avoid excess friction.

	Bearing Assembly	Driven gear
7.	Remove the rotation sensor from the engine.
8.	Apply Loc-tite to the mounting screws and install the crankcase plug supplied.
	Install bearing assembly, oil pump and rotation sensor
1.	Replace the o-ring on the bottom of the oil pump with the o-ring supplied.
2.	Install rotating magnet, oil pump, and rotation sensor to the coupler with original hardware
	Crankcase plug	Oil pump and rotation sensor on coupler
	Remove the fuel pump assembly
1.	Disconnect the fuel lines to fuel pump.
2.	Remove the 3 fuel pump mounting screws.
	Install EOI Pump and Controller Assembly
1.	Apply Loctite and install (3) #10-32 studs into the fuel pump bosses on the side of the block.
2.	Assemble (3) hex spacers on the studs and tighten against the bosses.
3.	Mount the EOI Pump and Controller assembly on the studs. Assemble the “J” clip on the upper right boss and secure with the (3) locknuts and washers provided.
	Pump and Controller assembly mounted on crankcase

	Carburetor link assembly
4.	Remove the throttle lever from the top carburetor. Install the link under the lever pointing down and to the left. Re-install the throttle lever and secure with the screw.
5.	Remove the rod end from the original link rod and assemble it to the new link rod.
6.	Connect and adjust the link rod to assure that the 1 st mark on the pump arm is in alignment with the first mark on the oil pump with the throttle at the idle position. See the Mercury Service Manual, for details .
7.	Bend the pump arm down to clear the controller if necessary.
	Relocate the fuel pump
1.	Disassemble the fuel pump from the mounting bracket .
2	Turn the mounting bracket over and assemble the pump as shown below .
3.	Assemble the fuel pump and bracket to the three bosses on the top of the block behind the flywheel .
4.	Fit and cut sections of new fuel line to reach the fuel pump.
5.	Splice the sections together with the brass fittings and secure with the clamps supplied.
6.	Assure that the fuel lines do not touch hot surfaces or interfere with linkages.
	Original Assembly	New Assembly
	Connect wiring
1.	Route the rotation sensor wires behind the EOI electric motor.
2.	Reconnect the white rotation sensor and white oil warning module wire.
3.	Connect the (3) blue/white rotation sensor, controller and oil warning module wires.
4.	Connect the black rotation sensor and black controller wire to a good ground on the block. Note that the black mounting studs are not good grounds.
5.	Disconnect the gray tachometer wire from the voltage regulator.
6.	Connect the gray controller wire to the gray voltage regulator wire and the gray tachometer wire with the “Y” adapter.
7.	Secure all wiring with the J-clip and cable ties supplied.
	Install oil lines
1.	Check that the 2 psi check valve opens between 1.5 and 2 psi. Replace if necessary.
2	Trim and install the new oil lines supplied. Reposition the oil pump fittings as needed.
3.	Secure the oil lines with the clamps supplied. Refill the oil reservoir and check for leaks .
	System test and start-up
1.	Connect the red wire to the starter solenoid and reconnect the battery.
2.	Re-connect the battery.
3.	Turn the ignition key to on and check for audible oil warning module signal. Do not deliver the engine to customer without an audible oil warning module signal.
4.	Start engine on pre-mix fuel and oil. Assure that the oil warning horn is not sounding. See the troubleshooting section if the horn is still sounding.
5.	Open the screw on the oil pump to bleed air out and assure oil flow, or remove the output oil line from the pump and observe oil flow. See the Mercury Service Manual for instructions.
6.	With the engine running, disconnect the blue-white rotation sensor wire and assure that the oil warning horn sounds. Reconnect the wire to stop the warning horn from sounding. Replace the oil warning module if the horn does not sound.
7.	If a VOM with a frequency scale (Hz) is available, clamp the red lead on the blue oil warning module wire connection and the black lead on ground. At 1000 engine RPM the frequency should be about 8 Hz, at 3000 engine RPM the frequency should be about 25 Hz.
8.	Spray electric motor and pump with Quicksilver Corrosion Guard in salt water areas.
9.	Deliver to customer and explain Operation and Maintenance Instructions.
	Troubleshooting
The warning horn may sound briefly if the throttle is advanced rapidly when running on a hose or when the impeller slips. This is normal and shows the sensitivity of the system. The horn sounds because the EOI electric motor needs a second or two to catch up with the engine speed. The EOI controller draws less than 20 milliamps when the engine is not running. The controller is not getting a good tachometer signal if the warning horn does not shut off after the engine is started .
1.	Check for correct and secure wire connections.
2.	Check that the voltage regulator is providing a good tachometer signal. Replace the voltage regulator if it does not properly drive the tachometer.
3.	Check all ground connections including the voltage regulator grounds .
4.	Install resistor spark plugs.
The controller is not getting a good rotation sensor signal if the warning horn comes on and stays on 10-15 seconds after the engine is started .
1.	Check for correct and secure rotation sensor wire connections. The blue wire Y connector on the controller must be connected to the blue-white wires from both the rotation sensor and the oil warning module.
2.	Check that the rotating magnet has been installed to drive the oil pump.
3.	Replace the rotation sensor.
Note: Do not connect the black and red motor wires on the controller to 12V battery voltage. Don not make unauthorized changes. Call Marine Solutions for Advice.