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Mercury 454 Magnum Installation Instructions Manual

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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
454/502 MagnumTBI_A1R9
1

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Summary of Contents for Mercury 454 Magnum

  • Page 1: Installation Instructions

    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 454/502 MagnumTBI_A1R9...
  • Page 2 @ 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 be too much restriction (ideally) or not enough (means you need more).
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.
  • Page 6 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.

  • Page 7: Symbol Key

    Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines OPEN CLOSED SYMBOL KEY Throughout this installation 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.
  • Page 8 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines WARNING Used to indicate precautions that must be taken to avoid bodily injury as well as damage to the supercharger and associated components. COMMON ABREVIATIONS Superc Pressure Engine Cool ant T...
  • Page 9 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.
  • Page 10 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”...
  • Page 11 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines NOTE. Mark and cut the intake gaskets to clear the galley pan mounts if required. See figure. Install new supplied intake gasket to cylinder head. NOTE. Apply a thick bead of black RTV silicone on the intake gaskets around the water passages to insure sealing around the water passages.
  • Page 12 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.
  • Page 13 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 Loctite threads to new longer crank pulley bolts and torque to 35 foot-pounds.
  • Page 14 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”...
  • Page 15 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines Fuel Pressure Regulator Injector Fuel Rail Fuel Cooler Inlet From Tank Electric Fuel Pump 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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 90 Degree Supplied Hose Cut Supplied Hose to fit Factory Power steering cooler (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.
  • Page 20 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.
  • Page 21 NOTE: After running the SC, the oil level will lower due to oil filling the bearings. The proper level should be between the bottom of the sight glass and the middle. Change SC oil every 50 HOURS and only use WHIPPLE SC OIL ONLY!! CAUTION Severe damage to the compressor will occur if you overfill the supercharger front gear case.
  • Page 22 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines WHIPPLE SC OIL LEVEL Fill to center of oil sight glass. 5.8 fl/oz. or 155cc. DO NOT OVERFILL, WILL VOID WARRANTY!! 26. WIRING INSTRUCTIONS: MEFI1 MUST UPGRADE TO MEFI3 OR MEFI4.
  • Page 23 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines Some may need to separate the supercharger from the intercooler housing by removing the 3 3/8” hex bolts to get to the injector connectors. If you separate them, clean the silicone from the 2 surfaces and reseal with black RTV silicone when putting back together.
  • Page 24 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines RELAY PIN LAYOUT Relay Pin Connection Wire Color To Fuel Pump + Orange Factory Pump Ground Black Battery Power + Factory Turn ON Wire Gray 25 Amp GM Relay Fuse 14089936...

  • Page 25: Before Starting The Engine

    Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 28. Throttle linkage installation: (See figure 8) Install factory throttle linkage anchor bolt into “L” adapter. Install factory throttle linkage bolt in throttle arm. Adjust linkage so that the linkage barely fits on the linkage bolt, so that the linkage is always being forced to it’s maximum closing position.
  • Page 26 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines to 1/8” pipe fitting on adjustable regulator. Prime fuel system so that filter is full of 91-octane gas. Turn key “on” and quickly bleed air from fuel line anywhere on pressure side.
  • Page 27 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines screw on regulator (clockwise for more pressure, counter clockwise for less) until you reach 40 lbs. of fuel pressure. Tighten nut on regulator so allen does not vibrate out. Install 5/32” vacuum/boost line onto regulator barbed fitting. Secure lines with zip ties.

  • Page 28: Post-Installation Checklist

    LAKE TEST POST-INSTALLATION CHECKLIST After installing the Whipple supercharger kit it is imperative that the following checklist be performed. Failure to perform these simple tests may result in severe engine damage. 1. Make sure 91 octane or higher is in the vessel. If unsure, then drain the tank completely...

  • Page 29: Maintenance And Service

    Install a quality fuel pressure gauge to the extra port at the auxiliary fuel rail added by Whipple (1/8” pipe). Attach the fuel pressure gauge with a long enough hose so that it may be visible during operation. Under WOT, full boost, max rpm, the fuel pressure should be 45 lbs (+/- 2lbs).
  • Page 30 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 7. Do not tee the vacuum/boost line feeding the Map sensor, 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.
  • Page 31 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 454/502 MagnumTBI_A1R9...
  • Page 32 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 454/502 MagnumTBI_A1R9...
  • Page 33 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 454/502 MagnumTBI_A1R9...
  • Page 34 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 454/502 MagnumTBI_A1R9...
  • Page 35 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines MEFI4 DIAGNOSTIC INFORMATION ONLY MEFI4 PIN CONFIGURATION J1 CONNECTOR J1 Pin Description Color Connector pin Connector Type J1-1 Knock signal #2 (N/A) Light Green (N/A) (N/A) J1-2 Diagnostic "test" terminal Black/White...
  • Page 36 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines FUEL PUMP RELAY Description Color Connector Pin 12V Power/B+ Relay #86 Trigger from ECM Dark Green/Black J1-6 Inj./ECM 10A fuse Black J2-19 Fuel pump trigger ON Gray Pin A Pin A...
  • Page 37 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines IAC MOTOR IAC B "LOW" Fuel INJ #1 15AMP IAC B "HIGH" IAC A "LOW" 10AMP IAC A "HIGH" Fuel INJ #2 15AMP Fuel INJ #3 Knock signal #2 (N/A) Fuel Pump Conn.
  • Page 38 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 454/502 MagnumTBI_A1R9...
  • Page 39 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 454/502 MagnumTBI_A1R9...
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  • Page 47 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 454/502 MagnumTBI_A1R9...
  • Page 48 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines 2-BAR MAP SENSOR SCALE Manifold PSI (KPA) 454/502 MagnumTBI_A1R9...

  • Page 49: Limited Warranty

    All merchandise manufactured by Whipple Industries is fully warranted against defects in workmanship and materials to the original purchaser of the Whipple Supercharger System. The limited warranty must be signed, dated and returned to Whipple Industries within 14 days of the purchase date accompanied by a copy of the original sales invoice.
  • Page 50 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines TRANSOM LEADING EDGE .375" BOTTOM OF BOAT 1.125" .75" WATER FLOW TRAILING EDGE For transom intercooler water pickups, install as shown in diagram. For engine water pickups, you want your trailing edge to only hang between .325-.625”.
  • Page 51 Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines Transom pickup Intercooler out Intercooler in Thru hull fitting Power steering Fuel cooler Oil cooler cooler Thru hull fitting Manifold bleed/drain (1/4" line) Engine block Sea pump Exhaust inlet Exhaust inlet...

This manual is also suitable for:

502 magnumMagnum 502