Mercury 454 Magnum MPI Tournament Ski User manual

Whipple 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
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
MUST KNOW INFORMATION!!
-EVERYBODY READ!!-
WATER FLOW – WATER FLOW – WATER FLOW
As of May 2002, Mercury Racing issued a service bulletin (attached to instructions) regarding engine
water block pressure. In this bulletin, it’s clear that Mercury Racing requires a minimum of 20-30lbs. of
engine water pressure at wide-open throttle (WOT). If this pressure is not achieved or not maintained,
you can have catastrophic engine failure of many types.
This leads us to your new supercharged engine. You’re no longer running a thermostat in the engine,
which was the largest water restriction in the stock system. Now, the largest restriction is the engine
itself, this means pressure is only increased by flow in this given application. Because you are taking
your stock engine and increasing the cylinder pressure for more peak power, to insure reliability, you
need more water to keep the engine cool and at the same time, you need more water pressure to keep
steam pockets from developing in your engine. With this in mind, you want a minimum of 25lpsi of block
pressure @ WOT, maximum 40psi @ WOT. If you do not have this pressure, you may hurt your engine.
Whipple 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 betoo much restriction (ideally) or
not enough (means you need more). With this information in mind, you must understand, you must
have more flow as well as pressure, if you restrict the outlet water too much and don’t have proper flow,
you will heat the engine up, still develop steam pockets and it could lead to engine failure.
•Ideally, the intercooler should be fed from a separate source. The intercooler does not need
constant water flow at slow speeds. This means a separate pickup can be installed solely for
the intercooler.
•You can run the intercooler off the drive side draft inlets, but never the engine.
•Mercury dual style water pickups do not let more water in, in fact, they have less water flow.
Always block off the side draft inlets if your boat uses them on this dual style drives.
•Never run the engine off side draft inlets in the drive, never!
•If you have a stepped bottom or high “X” dimension, water flow may be very low at high
speeds and caution must be taken.
•Test block pressure at various trim angles and in turns.
•Lower boost and or timing does not mean you’re safer with less water, if steam develops, the
engine will fail regardless, it needs pressure to push the steam out.
WATER FLOW – WATER FLOW – WATER FLOW
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
WHIPPLE CHARGER INSTALLATION INSTRUCTIONS
454/502 MAGNUM MPI STAGE 1
This product is intended for use on STOCK, UNMODIFIED, WELL-MAINTAINED ENGINES. Installation on a
worn-out engine is not recommended and could result in failure of the engine or the supercharger. It is
recommended to perform a compression test of all cylinders, and perform a cylinder pressure leak down
procedure, check and change spark plugs, spark plug wires, distributor cap, and rotor if necessary. This
will indicate the condition of the engine for reference. Whipple also recommends accurate fuel pressure
and water block pressure gauges for constant monitoring during operation.
This system is designed around the Delphi MEFI 3 and 4 ECM systems. If you have a MEFI 1, you will
need a new ECM and you’ll have to modify the harness at the end of the instructions. It’s a good idea
to review this as you may want to modify this during the middle of the installation.
It is the purchaser’s responsibility to follow all installation instruction guidelines and safety procedures
supplied with the product 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 responsibility for damages occurring from accident, misuse, abuse,
improper installation, improper operation, lack of reasonable care, or all previously stated reasons
resulting from incompatibility with other manufacturers’ products.
**NOTICE: Installation of Whipple Supercharger products
signifies that you have read this document and have
agreed to the terms stated within.
It is the purchaser’s responsibility to follow all installation instruction guidelines and safety
procedures supplied with the product 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 responsibility for damages occurring from accident, misuse,
abuse, improper installation, improper operation, lack of reasonable care, or all previously stated
reasons resulting from incompatibility with other manufacturers’ products.
There are no warranties expressed, implied, for merchantability or fitness for
engine failure, parts failure, any type of damage to vessel in any way, or
reimbursement for labor or inconvenience.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
YOU MUST SEND YOUR ECU IN FOR REPROGRAMMING TO WORK WITH THE WHIPPLE
SUPERCHARGER SYSTEM. THERE ARE REPLACEMENT ECU’S AVAILABLE. ACCOMPANY EACH
COMPUTER WITH NAME, SHIPPING INFORMATION, CONTACT INFO, BOAT INFO AND IF ANY
MODIFICATIONS HAVE BEEN MADE TO THE ENGINE. WHIPPLE WILL PAY FOR STANDARD GROUND
FREIGHT IN THE CONTINETAL U.S. IF YOU WANT FASTER SERVICE OR SHIPPING FROM FROM
OUTSIDE THE CONTINENTAL U.S., PROVIDE PAYMENT INFORMATION FOR FREIGHT. SEND FACTORY
ECU TO:
WHIPPLE SUPERCHARGERS
ATTENTION: MARINE ECU RECAL DEPARTMENT
3292 N. WEBER
FRESNO, CA 93722
559.442.1261
For best performance and continued reliability the following are MANDATORY.
1. USE ONLY PREMIUM GRADE FUEL (91 OCTANE OR BETTER). NEVER USE LOWER OCTANE.
2. ALWAYS LISTEN FOR ANY SIGN OF ENGINE KNOCKING, IF PRESENT DISCONTINUE 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, IGNITION
TIMING OR THE RPM LIMITER, NOTHING!) THIS COMPLETE SUPERCHARGER SYSTEM IS DESIGNED
AND ENGINEERED TO MAXIMUM PERFORMANCE FROM THE WHIPPLE CALIBRATION. ANY
MODIFICATIONS TO PROGRAM MAY CAUSE SERIOUS DAMAGE TO THE ENGINE.
WARNING! The most important precaution you must take with the WHIPPLE CHARGER is cleanliness.
This supercharger is a high quality, close tolerance compressor that cannot be subjected to dirt or any
type of foreign material. Foreign material entering the supercharger will automatically void all warranties.
DO NOT remove the protective seal on the supercharger prior to installation.
This system requires a major fuel system modification. Use extreme caution around the high flammable
fuel and fuel vapors.
Always wear appropriate safety goggles and gloves when required.
Always use caution around flammable liquids. 1
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
SYSTEM PERFORMANCE INFORMATION
A Mercruiser scanner is an electronic tool used to display various engine parameters. This scanner
can be installed and monitor all engine parameters while the boat is being operated. Some of these
are items are: RPM, TPS volts, KNOCK RETARD, COOLANT temp, IAC counts, and any TROUBLE
CODES. You can also put the engine in the set timing mode. You can purchase this scanner at
Whipple Industries for $600.
1. TPS Voltage Setting- Before starting your engine, you must set the TPS voltage utilizing a
MerCruiser scan tool or a standard 0-5v volt meter. The proper TPS voltage is between .50 - .55
volts. The TPS is a 5v sensor. The blue wire is the signal wire.
2. Idle speed setting- Your modified ECU has a “desired” idle speed that varies with engine temp.
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 gear. If you have a scan tool, timing should bounce in the positive range, approx. 0-16,
if it’s constantly lower, it needs more air. If it’s constantly higher (in neutral), then it needs less air.
For the IAC counts, 150 is max wide open meaning that its allowing as much air into the system as
possible, while 0 counts means the IAC is closed, it is not allowing air into the system. If the counts
are to low, adjust the closed throttle stop to close the throttle. If the counts are to high, adjust the
throttle to open more. Although this number will move, in neutral, you want it to start high when
engine fires and then count down to 0-40 counts. This will allow it to open to max when engine is
shifted into gear.
Note: The engine must be turned off for 5 seconds and re-started to p operlyreset
the learning of the IAC system. r
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
3. Check cooling system water pressure. The cooling system must be able to operate efficiently.
Optimal performance and reliability will be gained if an external pick-up is installed for the Whipple
Intercooler water. To check the performance of your cooling system, install a 0-50psi. pressure
gauge on the water drain plug located on the bottom center of the block. The idle pressure may read
0-3psi. and full speed/RPM may read over 30psi. The minimum pressure allowed, for proper engine
cooling, is 30psi at WOT. 40psi should be the maximum, if exceeded, please contact Whipple
Industries. The reading should be obtained at high speed and high RPM. If the pressure 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 system,
so block pressure must be checked before and after.
4. MEFI Engine management system. If your engine has a MEFI 1 ECM, your system mustbe updated
to a MEFI 3 or 4 system. Follow the wire diagram at the end of the manual for converting.
4. Supercharger By-pass system. The supercharger is installed with a by-pass system. This allows
the supercharger to operate at higher efficiency under vacuum operation. It is advised to verify the
operation of the bypass valve. At idle and low engine loads, the bypass will be open. At higher loads
(engine in boost) the bypass will be closed. As the throttle is opened quickly the bypass valve will
close momentarily. This verifies the bypass will close and is functioning.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
SYMBOL KEY
Throughout this installation guide you will see the following symbols used:
ÂNOTE
Used to indicate tips and information to aid in installation, maintenance, or use of the
supercharger.
!! CAUTION !!
Used to indicate precautions that must be taken to avoid damage to the
supercharger and associated components.
OPEN
CLOSED
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
ÌWARNING!!
Used to indicate precautions that must be taken to avoid bodily injury as well as
damage to the supercharger and associated components.
COMMON ABREVIATIONS
SC Superc gerhar
PSI Pressure
ECT Engine ant TCool emperature
IAT Inlet A mperir Te ature
IAC Idle Air Control
TPS Thrott itionle Pos Sensor
MAP Manifo olutld Abs e Pressure
PCV Positiv nkcae Cra se Ventilation
WARNING!! CONSTANT ABUSE OF THE REV
LIMITER WILL 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 batteries.
2. Removal of stock parts:
(SERP) Loosen the stock adjustable idler nut to release tension of belt, remove the
stock belt.
(VBELT) Loosen accessories and remove factory v-belts.
Remove the factory crank pulley and clean the front surface, the new SC crank
pulley will mount to the surface of this later.
Unplug factory electrical plugs: Idle Air Control connector, Inlet Air Temp connector,
both Engine Coolant Temp connectors, Manifold Absolute Pressure connector, both
distributor connectors.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
Remove stock throttle linkage and throttle body (throttle cable bolt and IAC motor)
and flame arrestor.
Remove factory shift cable bracket and mount on transom.
Loosen the belt tensioner holding nut. Release the tension on the Poly-V belt
and remove belt.
Remove the self-locking nut and washer holding throttle cable to the throttle
shaft and washer.
Install stock IAC motor on new throttle body with stock o-rings and stock torx.
Remove PCV valve and hose from intake manifold/valve cover.
Remove the distributor (replace if more than 100 hours or 2 seasons, only use
Mercury Marine distributors, other aftermarket replacements are not compatible with
the MEFI system). Note: It helps to mark the position of the distributor before
removal so it can be stabbed much closer to 8 degrees. You can take the distributor
cap off, crank engine over until pointer faces directly 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).
Remove factory fuel lines and unplug factory fuel pump. Leave cool fuel unit in
place.
Inspect factory fuel line from tank. Make sure there are no restrictions such as
check valves, tight bends or anything smaller than 3/8” ID. Remove or replace any
restrictions found.
Remove thermostat housing and all it’s connecting hoses.
Remove entire intake manifold, both bottom and top assembly. Note: Must unplug
all injector connectors before removing and pull away from fuel rail.
Push factory-wiring harness to backside of motor so it’s out of the way.
Remove stock sensors from intake such as intake air temp sensor (located above #7
runner on intake) and 2 coolant temp senders (gauge and ECU).
Remove stock circulating water pump from block and all of it’s connecting hoses.
(SERP) Remove stock adjustable idler support bracket from engine (this requires
loosening of other brackets, reinstall them when done removing idler bracket).
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
(VBELT) Remove mechanical fuel pump from sea pump assembly and install
supplied fuel pump block off plate with the 3/8” x ½” socket head allens.
Separate the intake manifold from the intercooler/SC assembly by removing the 8
3/8” hex bolts.
3. Install factory sensors:
Install stock coolant temp sensors in new intake manifold by installing the single
post gauge sender into portside NPT port. Install the ECM sender (yellow/black
wires) to port side NPT. Use teflon pipe sealant on threads of sensors.
Install Inlet Air Temp sensor into 3/8” NPT located on the backside of manifold.
4. Intercooler and engine block water dump fittings: DO NOT RESTRICT OUTLET
Find visible location for both dumps above the water line. Remember, if you install
the stainless tee for the intercooler, it will run all the time, even when idling.
Mark your spots on the boat, and drill a hole using a ¾” 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 outside of boat, install the
supplied aluminum 8AN nut and tighten. Do the same for both thru-hull fittings.
Apply thread sealant to threads of supplied ¼” tee’s male thread. Install tee fitting
into thru-hull dump fitting that is tapped ¼” NPT. Install the 2 ¼” 90 degree
barbed fittings (apply thread sealant) into female ends of tee fitting.
Once tightened, wipe the excess silicone off and let the silicone dry.
5. (MEFI 1) You must upgrade to MEFI 3 or MEFI 4 ECM’s. It’s best to do the wiring mods
before you install the supercharger. Follow the wiring diagram at the end of the
instructions.
NOTE: It is beneficial to skip to instruction 23 at this time so you can install the
injector connectors while you have the blower off the intake.
6. Intake manifold installation:
Clean intake manifold and cylinder head surface.
ÂNOTE. Apply thick bead of RTV silicone around all 4 water passages on cylinder heads.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
ÂNOTE. Mark and cut the intake gaskets to clear the galley pan mounts if required. See
figure.
Install new supplied intake gasket to cylinder head.
ÂNOTE. Apply a thick bead of black RTV silicone on the intake gaskets around the water
passages to insure sealing around the water passages.
ÂNOTE. 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 2.25” socket head
allens and the .680” stainless washers. Torque to 20 foot-pounds on your first pass,
torque to 35 foot-pounds on your second pass. Note: Install all bolts hand
tight and slide intake forward as much as possible, and then stab the
distributor to make sure everything lines up. If it does, proceed, if it does
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
not, you may have to file one of the openings, contact Whipple first.
Line up the distributor housing to the rotor as you marked previously. If it does not
line up, remove distributor and insert a screwdriver into the hole to turn the oil
pump drive shaft. Repeat this adjustment as needed until the distributor can be
firmly seated and all componets are in alignment.
Install hold down clamp over distributor and bolt it securely.
Reinstall distributor cap and secure in place.
Install the supplied manifold to intercooler housing gasket.
Install supercharger/intercooler assembly by lying on intake manifold with throttle
cable assembly as well. NOTE: While installing SC/intercooler assembly, you must
install the 3/8” x 1.5” hex bolt in the first throttle cable bracket/intercooler mounting
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 35ft. lbs.
Install new thermostat housing with the supplied 3/8” x ¾” socket head allen bolts
and new thermostat gasket. If installing the water restrictor, install flat side into
intake manifold thermostat register. Install supplied 3/8” x ¾” socket head allen in
extra 2 blank holes, use pipe sealant on threads. NOTE: Do not install a
thermostat, this system is made to run with NO THERMOSTAT.
7. Install spark plug wires (replace if you have over 100 hours or 2 seasons on current wires). Firing
order is 1-8-4-3-6-5-7-2. (Whipple recommends MSD 8.5mm plug wires)
1 2
87
4 5
36
1
2
87
45
3
6
F
R
O
N
T
It is recommended to use a few tie straps for this step: they’re cheap!!!
8. Make sure the mounting surface of the new crank pulley on the front of the balancer is
perfectly flat. If necessary, remove the imperfections or paint with a good flat file.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
(SERP) Install the Whipple dual serpentine crank pulley on the factory balancer
utilizing the 3/8” x 2.5” hex head bolts. Each bolt should get 1 AN flat washer (goes
against crank pulley) and lock washer. Apply a small amount of Red LoctiteTM on
threads to new longer crank pulley bolts and torque to 35 foot-pounds.
(VBELT) Install the Whipple triple V/serpentine crank pulley on to the factory
balancer utilizing the 3/8” x 3.5” hex head bolts. Each bolt should get 1 AN flat
washer (goes against crank pulley) and lock washer. Apply a small amount of Red
LoctiteTM on threads to new longer crank pulley bolts and torque to 35 foot-pounds.
9. Stainless water cross-over system:
(VBELT) Install stainless water cross over utilizing the new gaskets and 4 3/8” x ¾”
socket head allen bolts. Inlet feed 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
spacers that fit against the water cross over and through the new plate, use the 2 -
3/8” x 3.5” socket head allens and washers to secure starboard side of plate. See
figure 2 and following diagram. On the port side, use the supplied oil
cooler/power steering support bracket with 2 3/8” x 3.75” socket head allen bolts.
10. Front plate/support installation:
Take the round support stands and tighten on setscrews. Tighten using the hex
area on stand.
Take front plate assembly and slide collar and front plate over the drive just slightly.
NOTE: ¼” allens in collar are not tight, must apply blue Loctite.
Install the 3/8” X 1” socket head allen bolts hand tight through front plate to support
stands and follow by aligning front plate with SC pulley and support stands. The
drive collar must be tightened evenly, do not just tighten the button head allen
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
bolts, snug the collar locking bolt and the collar to plate bolts.
Once aligned, remove blower pulley for access to drive collar bolts.
Remove drive collar socket head allen bolts one at a time so you don’t lose your
alignment, apply light amount of blue Loctite and tighten ¼” socket head allens on
collar.
Tighten the 3/8” x 1.5” button head allen bolts into support stands to secure front
plate. Torque to 22 ft. lbs.
Install blower pulley with the supplied 6mm x 14mm socket head allen bolts. Hold
drive hub from spinning by using a large metric allen in center of drive hub. Then
tighten blower pulley bolts to 120 inch pounds. NOTE: Install dry, no Loctite.
11. There are two ways of routing your fuel system. Ideally, you want to return all fuel to an
open port in the fuel tank(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 port for return, then you must utilize the fuel cooler and
inlet tee for returning fuel.
12. Assemble fuel pressure regulator:
Install barbed brass fitting with o-ring (be very careful, very breakable).
Install adjusting set screw and nut, do not install tight at this time.
Install –6 o-ring to –6 AN flare fitting into return side of regulator.
Install supplied 1/8” pipe plug into fuel pressure regulator. Apply light amount of
thread sealant to threads.
Install the –10 oring to the –10AN to –6AN fuel fitting (93-98 MEFI1 ONLY).
Install the –10AN to –6AN fuel fitting into either side of regulator (93-98 MEFI1
ONLY).
Install the –10AN plug fitting into fuel pressure regulator (either side) (93-98
MEFI1 ONLY).
13. Remote mount fuel pressure regulator with the supplied bracket and hardware. Ideally this
should be within 3 feet of the fuel rail.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
Electric Fuel
Pump
Inlet From Tank
Injector Fuel Rail
Fuel
Cooler
IN
OUTOUT
IN
Fuel Pressure
Regulator
14. (93-98 MEFI1) Fuel system installation: NOTE: Never use thread/pipe sealant on o-ring
style fuel fitting.
Inspect factory fuel lines from tank(s), check for any restrictions such as check valves
and inline filters. All restrictions must be removed to allow proper fuel flow.
Remove factory fuel lines and fittings from stock fuel filter.
Install supplied ¼” NPT brass Tee to the stock fuel filter IN. Apply light amount of pipe
sealant to pipe thread.
Install factory barbed fitting into Tee fitting. Install factory 3/8” ID fuel hose from tank
and tighten clamp.
Install (1) ¼” NPT pipe to –6AN fuel fitting into ¼” NPT
brass tee fitting.
IN
OUTOUT
IN
Install (1) ¼” NPT pipe to –6AN fuel fitting in the stock
fuel filter OUT.
Install supplied –10AN (3) o-rings to the –10AN to –6AN
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
fuel fittings.
Install the supplied (2) –10AN flow to –6AN flare fittings in the inlet and outlet ports of
the new hi-flow fuel pump.
Install supplied (1) –10AN flow to –6AN flare fitting into inlet of fuel PSI regulator
(either side will work). Install supplied –10AN plug to empty inlet port of fuel PSI
regulator.
Pre-plan the fuel line routing so you can mount the fuel pump and fuel cooler in proper
locations. It’s best suited to install pump at a lower level than the fuel tank.
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 pipe sealant to fuel cooler –6AN steel fittings. Install fittings to cooler.
Find a secure mounting location for the fuel cooler, mount cooler. This can be located
anywhere in the factory water system after the sea pump outlet.
You must now manufacture fuel lines. Use only high quality, USCG
approved, high-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 fuel line utilizing 3/8” ID hose from the pump OUTLET to the –6 fitting on
the starboard side of the fuel rail –6 fitting.
Manufacture fuel line utilizing 3/8” ID hose from the port side fuel rail –6AN fitting to
the –6AN fitting to the inlet of fuel PSI regulator.
Manufacture a fuel line utilizing 3/8” ID fuel line from the regulator return to the new
supplied fuel cooler.
Manufacture another 3/8” ID fuel line from the fuel cooler to the –6 fitting you installed
into the brass ¼” Tee fitting (IN @ fuel filter).
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 and kinks.
15. (99-2002 MEFI3) Fuel system installation: NOTE: Never use thread/pipe sealant on o-
ring style fuel fitting.
Inspect factory fuel lines from tank(s), check for any restrictions such as check valves
and inline filters. All restrictions must be removed to allow proper fuel flow.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
Remove factory fuel lines and fittings from stock fuel filter except for factory inlet.
Install supplied ¼” NPT pipe to 3/8” barbed fitting into
the stock fuel filter IN #1. Apply light amount of pipe
sealant to pipe thread. Face barbed fitting straight
down.
IN #1
OUT #1OUT #2
IN #2
Install (1) ¼” NPT pipe to –6AN fuel fitting in the stock
fuel filter OUT #1.
Install (1) ¼” NPT pipe to –6AN fuel fitting in the stock
fuel filter IN #2.
Install supplied –10AN (3) o-rings to the –10AN fuel fittings.
Install the supplied (2) –10AN flow to –6AN flare fittings in the inlet and outlet ports of
the new hi-flow fuel pump.
Install supplied (1) –10AN flow to –6AN flare fitting into inlet of fuel PSI regulator
(either side will work). Install supplied –10AN plug to empty inlet port of fuel PSI
regulator.
Pre-plan the fuel line routing so you can mount the fuel pump and fuel cooler in proper
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, mount pump in clamps using the supplied
brackets, and tighten clamps. Make sure the rubber strips are on straight.
Install pipe sealant to fuel cooler –6AN steel fittings. Install fittings to cooler.
Find a secure mounting location for the fuel cooler, mount cooler. This can be located
anywhere in the factory water system after the sea pump outlet.
Install factory fuel line from tank to barbed fitting, secure with factory clamp (utilize
factory fuel line and clamp that routed to the first stock fuel pump).
You must now manufacture fuel lines. Use only high quality, USCG
approved, high-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 fuel line utilizing 3/8” ID hose from the pump OUTLET to the –6 fitting on
the starboard side of the fuel rail –6 fitting.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
Manufacture fuel line utilizing 3/8” ID hose from the port side fuel rail –6AN fitting to
the –6AN fitting to the inlet of fuel PSI regulator.
Manufacture a fuel line utilizing 3/8” ID fuel line from the regulator return to the new
supplied fuel cooler.
Manufacture another 3/8” ID fuel line from the fuel cooler to the –6AN fitting you
installed into filter 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 and kinks.
Electric Fuel
Pump
Inlet From Tank
Injector Fuel Rail
Fuel Pressure
Regulator
Fuel
Cooler
IN
OUTOUT
IN
Fuel Pressure
Check Point
16. Water routing:
(SERP) Use the supplied “U Bend” hose to connect too water crossover inlet
(figure 4) from the factory oil cooler. Cut supplied hose and fit so there are no
kinks of any kind (see following diagram for reference). Secure hose with factory
clamp off.
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
Factory
Power
steering
cooler
90 Degree
Supplied Hose Cut Supplied
Hose to fit
(SERP) Install intercooler water supply (preferably separate pickup) from external
pickup or supplied tee. The tee should be installed after the sea pump, 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 or hose coupler.
Cut hose to fit. Some hoses may need to be replaced if worn or cracked.
Factory
Power
steering
cooler
90 Degree
Supplied Hose
Factory
hose, cut to
fit
Intercooler tee or hose
coupler
Install supplied 5/8” ID hose from intercooler tee to the port side –10AN intercooler
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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
inlet and secure with #10 hose clamps.
Install 5/8” ID hose from starboard side intercooler fitting and route to fuel cooler
and secure with #10 hose clamps.
Route 5/8” ID hose from fuel cooler to intercooler dump fitting you installed earlier.
Install brass – 8 push lock fitting to intercooler dump fitting and follow by pushing
the 5/8” ID hose on push lock fitting.
Install factory hose and clamps to new thermostat housing and bottom water feed
on stainless exhaust.
Install supplied tee with dual ¼” fittings and male pipe into the thru-hull fittings that
is threaded on the inside. Use pipe sealant on all fittings.
Make up ¼” ID hose from the fittings coming out of the back of the intake manifold
to the water dump fitting with the tee installed. Secure with hose clamps.
17. Take factory PCV valve and take straight plastic top off. 93-97 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 valve.
Insert PCV valve in port side valve cover. Route hose to 90 degree fitting on throttle
body as shown in figure 5.
18. Utilize the factory 1/2” hose that was used on the breathers to install the small breather.
You may mount this wherever you want, or cut real short and let it sit there (see figure 6).
Secure both ends with #6 hose clamps.
19. Install factory 6 rib grooved idler on Whipple plate on diagonal position with adjusting
setscrew up and down. Use the tee nut to slide back and forth, the idler spacer to space
idler out correctly and the idler washer that centers the hex bolt on front side of idler
bearing.
20. (VBELT) Install the 2 new supplied v-belts to accessories. You will reutilize one factory
belt.
21. (SERP) Install new 6 rib belt as shown in this diagram: Once installed tighten by using the
all thread stud on the bottom of the idler as shown in following diagram.
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