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Whipple Charger Installations Instructions for Mercury 454/502 Magnum Engines
empty and fill with 91 or higher.
2. With the thermostat removed, under full throttle operation, near full speed, block pressure
should be a minimum of 25lbs. and maximum of 40lbs. If block pressure is not present,
severe engine damage may occur. The motor should have 0-2lbs. at idle and should
progressively get higher as speeds increase. A low water nose style pickup or external pickup
may need to be installed. The Mercury side hole pickups will not generate enough water flow
for proper operation. If you have an XZ drive with dual water pickups, it WILL be necessary
to plug side draft holes to increase pressure.
3. Fuel pressure is the most critical parameter and must be checked during wide-open throttle
operation. 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). This procedure takes two people – one to drive and the other to
observe the gauge. Perform the test in a safe area. If it does not maintain fuel pressure, you
must find the restriction, as this results in a lean air to fuel condition.
It is recommended that the following items be checked at normal service intervals.
1. Check supercharger oil every 10-15 hours of operation.
2. Clean idle air motor filter every 10-15 hours.
3. Remove and clean flame arrestor elements every 10-15 hours.
4. Change supercharger oil every 50 hours or every season, which ever comes first.
5. Check the supercharger/accessory drive belt. Adjust or replace as required.
6. Inspect and replace fuel filter every 50 hours.
7. Replace factory spark plugs every 50 hours.
8. Back flush intercooler every 50 hours or once a season.
9. Follow your standard Mercury Marine service intervals.
1. Never run octane less than 91.
2. Do not use octane booster, these are very hard on the spark plugs and only increase a few
points. Example: 87 octane with octane booster, may raise a few "points" to 87.5, which is
not acceptable.
3. Never operate engine if overheating.
4. Never operate engine in boost if water temp exceeds 140.
5. Do not operate engine in boost if water pressure has fallen below standard levels.
6. Do not operate engine in boost if fuel pressure falls below standard levels.
454/502 MagnumTBI_A1R9
MAINTENANCE AND SERVICE
DO NOT!!!
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