Electrical Systems: Wiring Diagrams
Electrical Systems: Wiring Diagrams
Electrical Systems: Wiring Diagrams
4
D
72938
WIRING DIAGRAMS
INDEX
Table of Contents
Page
Wiring Colors for MerCruiser . . . . . . . . . . . . . . . 4D-1
Wire Color Abbreviations . . . . . . . . . . . . . . . 4D-1
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2
MCM 3.0L/3.0LX . . . . . . . . . . . . . . . . . . . . . . 4D-2
MCM V-6 Alpha Drive Engines . . . . . . . . . . 4D-3
MCM V-8 Alpha Drive Engines . . . . . . . . . . 4D-4
MCM V-8 Bravo Drive Engines . . . . . . . . . . 4D-5
MIE V-8 All Inboard and Ski Engines . . . . . 4D-6
MCM Quicksilver Instrumentation . . . . . . . . 4D-7
MIE Quicksilver Instrumentation . . . . . . . . . 4D-8
Dual Station Wiring (Using a Neutral Safety
Switch in Only one Remote Control) . . . . . . 4D-9
Dual Station Wiring (Using A Neutral Safety
Switch In both Remote Controls) . . . . . . . . 4D-10
Dual Station Wiring (Using a Neutral Safety
Switch in Engine Wiring Harness) . . . . . . . 4D-11
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-12
Battery Meter Gauge . . . . . . . . . . . . . . . . . . 4D-12
Cruiselog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-12
Fuel Gauge and Sender . . . . . . . . . . . . . . . 4D-12
Audio Warning System . . . . . . . . . . . . . . . . 4D-13
Water Temperature Gauge . . . . . . . . . . . . . 4D-13
Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . 4D-13
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-13
Wiring Diagrams for 502 EFI . . . . . . . . . . . 4D-15
EFI Wiring Diagram . . . . . . . . . . . . . . . . . . . 4D-17
ECM Component Connector Charts . . . . . . . 4D-21
INDEX
4D - WIRING
4D-0 DIAGRAMS
- WIRING DIAGRAMS 90-806535 893
Wiring Colors for MerCruiser
BIA Color Code Where Used
Black All Grounds
Brown Reference Electrode-MerCathode
Orange Anode Electrode-MerCathode
Lt. Blue/White Trim- ”Up” Switch
Gray Tachometer Signal
Green/White Trim -”Down” Switch
Tan Water Temperature Sender to Gauge
Lt. Blue Oil Pressure Sender to Gauge
Pink Fuel Gauge Sender to Gauge
Brown/White Trim Sender to Trim Gauge
Purple/White Trim-”Trailer” Switch
Red Unprotected Wires from Battery
Red/Purple Protected (Fused) Wires from Battery
Red/Purple Protected (+12V) to Trim Panel
Orange Alternator Output
Purple/Yellow Ballast Bypass
Purple Ignition Switch (+12 V)
Yellow/Red Starter Switch to Starter Solenoid to Neutral Start
Switch
Wire Color Abbreviations
BLK Black
BLU Blue
BRN Brown
GRY Gray
GRN Green
ORN Orange
PNK Pink
PUR Purple
RED Red
TAN Tan
WHT White
YEL Yellow
LIT Light
DRK Dark
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-1
Wiring Diagrams
MCM 3.0L/3.0LX
2
1
3
4
1 2
1 6
2
4 5
INDEX
4D-2 - WIRING DIAGRAMS 90-806535 893
MCM V-6 Alpha Drive Engines
1
1
2
2
WHT/RED
WHT/GRN
GRY 3
PUR
1 3
4
2
4
5
2 3
71877
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-3
MCM V-8 Alpha Drive Engines
1
1
2 3
WHT/RED
WHT/
GRN
GRY 3
1 3
PU
R
1
5
2
72935
INDEX
4D-4 - WIRING DIAGRAMS 90-806535 893
MCM V-8 Bravo Drive Engines
2
3
WHT/RED
WHT/GRN
GRY
1 2
PUR
4
3
72936
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-5
MIE V-8 All Inboard and Ski Engines
WHT/
RED
WHT/
GRN
GR 1
Y
PU
R 2
2
3 4
1
5 72937
NOTE : Taped back brown and black wire may be used for an accessory. LOAD MUST NOT EXCEED 5 AMPS
A-Ignition System 6 -StarterSlave Solenoid
1 -Distributor C -Audio Warning System
2 -Ignition Coil 1 -Water Temperature
2 -Transmission Fluid Temperture
B -Starting and Charging System 3 -Oil Pressure
1 -Alternator
2 -Ground Stud D -Instrumention System
3 -Starer Motor 1 -Oil Pressure Sender
4 -Circuit Breaker 2 -Water Temperature Sender
5 -Neutral Safety Switch
INDEX
4D-6 - WIRING DIAGRAMS 90-806535 893
MCM Quicksilver Instrumentation
1 2
3 4 5
6 B
S
I 7
72938
NOTE 1: Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene to connection and
slide rubber sleeve over connection.
NOTE 2: Power for a second fused accessory panel may be tasken from this connection. Load MUST NOT exceed
35-40 amps. Panel ground wire MUST BE connected to instrument terminal that has an 8 gauge black (ground)
harness wire connected to it.
1 - Tachomter
2 - Audio Warning Buzzer (if Equipped)
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
6 - Ignition Switch
7 - Trim Indicator
8 - To 12 Volt Source (purple wire connection)
9 - 20 Ampere Fuse
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-7
MIE Quicksilver Instrumentation
2
1
4 5
3
6 B
S
I
72939
NOTE 1: Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene to connection and
slide rubber sleeve over connection.
NOTE 2: Power for a second fused accessory panel may be tasken from this connection. Load MUST NOT exceed
35-40 amps. Panel ground wire MUST BE connected to instrument terminal that has an 8 gauge black (ground)
harness wire connected to it.
1 - Tachomter
2 - Audio Warning Buzzer (if Equipped)
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
6 - Ignition Switch
7 - To 12 Volt Source (purple wire connection)
8 - 20 Ampere Fuse
INDEX
4D-8 - WIRING DIAGRAMS 90-806535 893
Dual Station Wiring (Using a Neutral Safety Switch in Only one Remote Control)
A 1
2
3 4 5
L GND
T SW
UNSW GND
L GND L GND L
12V
T 12V T 12V T 12V
PUR
GRY
LT. BLU
PUR
PUR
PUR
BLK
BLK
BLK
BLK
BLK
TAN
YEL/RED
GRY
PUR
NOTE 3
YEL/RED
NOTE 1
1 2 3 5
RED/PUR 4 BRN/WHT
GND
L
B T SW UNSW
SI GND L GND GND
L L
12V T T
12V 12V T 12V
ORN
PUR
PUR
TAN
BLK
BLK
LT. BLU
RED/PUR
BLK
YEL/RED
ORN
BLK
GRY
PUR
NOTE 2
PUR
PUR
YEL/RED
NOTE 3
NOTE 3
NOTE 3
NOTE 1
BRN/WHT
YEL/RED
B YEL/RED 6
72940
NOTE 1: Brown/white wire is taped back at instrument end. If installing on boat that is equipped with MerCruiser Stern Drive, brown/white
wire is connected to trim sender terminal block. If installing on MerCruiser Inboard, brown/white wire is taped back at engine end, or it may
be used for an accessory (limit 5 amperes)
NOTE 2 : An accessory fuse panel may be connected at this location. The combined current draw of the primary station and secondary
station MUST NOT exceed 35 amperes.
NOTE 3 : Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene to connection and slide rubber sleeve over
connection.
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-9
Dual Station Wiring (Using A Neutral Safety Switch In both Remote Controls)
A 2
1 3 4 5
L GND
T SW
UNSW L
L L GND GND
12V GND T
T T
12V 12V 12V
PUR
YEL/RED
GRY
LT. BLU
PUR
PUR
PUR
BLK
BLK BLK
BLK
BLK
TAN
YEL/RED
GRY
PUR
NOTE 3
NOTE 3
YEL/RED NOTE 1
1 2 3 5
RED/PUR 4 BRN/WHT
GND
L
B T SW UNSW
S L GND L GND L GND
I T
12V T 12V T 12V
12V
7 SIG
SEND SEND SEND
ORN
BLK
RED/PUR
PUR
PUR
TAN
LT. BLU
BLK
BLK
GRY
YEL/RED
PUR
NOTE 2
ORN
BLK
PUR PUR
NOTE 3
YEL/RED
NOTE 1 YEL/RED
NOTE 3 BRN/WHT NOTE 3
YEL/RED
B YEL/RED
72941
NOTE 1: Brown/white wire is taped back at instrument end. If installing on boat that is equipped with MerCruiser Stern Drive, brown/white
wire is connected to trim sender terminal block. If installing on MerCruiser Inboard, brown/white wire is taped back at engine end, or it may
be used for an accessory (limit 5 amperes)
NOTE 2 : An accessory fuse panel may be connected at this location. The combined current draw of the primary station and secondary
station MUST NOT exceed 35 amperes.
NOTE 3 : Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene to connection and slide rubber sleeve over
connection.
A 1
2
3 4 5
L GND
T SW
UNSW L
L L GND GND
12V GND T
T T
12V 12V 12V
PUR
GRY
LT. BLU
PUR
PUR
PUR
BLK
BLK BLK
BLK
BLK
TAN
YEL/RED
GRY
PUR
NOTE 3
YEL/RED NOTE 1
1 2 3 4 5
RED/PUR BRN/WHT
GND
L
B T SW UNSW
S L GND L GND L GND
I 12V T T 12V T 12V
12V
7 SIG
SEND SEND SEND
ORN
BLK
BLK
PUR
PUR
TAN
LT. BLU
RED/PUR
BLK
PUR
GRY
YEL/RED
ORN
BLK
PUR PUR NOTE 2
6
YEL/RED
NOTE 3
NOTE 3
NOTE 1
BRN/WHT YEL/RED
NOTE 3
B
72942
NOTE 1: Brown/white wire is taped back at instrument end. If installing on boat that is equipped with MerCruiser Stern Drive, brown/white
wire is connected to trim sender terminal block. If installing on MerCruiser Inboard, brown/white wire is taped back at engine end, or it may
be used for an accessory (limit 5 amperes)
NOTE 2 : An accessory fuse panel may be connected at this location. The combined current draw of the primary station and secondary
station MUST NOT exceed 35 amperes.
NOTE 3 : Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene to connection and slide rubber sleeve over
connection.
Note 1
3
c
4 2
1
b
PNK
72814
BLK
BLK
. . (or+) Terminal on Water Temperature or Oil Pressure
Gauge
c - Black Jumper Wire from This Terminal to Ground
Terminal on Water Temperature or Oil Pressure Gauge
72816
Note 2
Note 1: Connect terminal to Ignition or Accessory Terminal of Igni-
Cruiselog tion.
Note 2: Connect to Negative Battery Terminal or Suitable Ground.
a 1 - Tank Sender
2 - Sender Capsule
3 – Fuel Gauge (Black Case)
72815
INDEX
4D-12 - WIRING DIAGRAMS 90-806535 893
Audio Warning System Oil Pressure Gauge
! WARNING
Buzzer is not external ignition-proof; therefore,
DO NOT mount buzzer in engine or fuel tank
compartments.
4
3
PUR
2 1
RED
3
72819
TAN/BLU
1 - Ground (Black)
1 TAN/BLU 2 - Switched 12 Volt Terminal (PURPLE)
3 - Sender Lead (LIGHT BLUE)
72817
Clock
2
1 - Audio Warning Buzzer
2 - Water Temperature Switch
3 - Oil Pressure Switch
4 - 12 Volt Power Source
3
Water Temperature Gauge
2
1 72818
1 - Connect Wire (DARK BLUE)to an Ignition Terminal of an
Adjacent Gauge or to Any Switched 12 Volt Terminal.
2 - Connect to Instrument Harness (RED/PURPLE) Lead and
Slide a Rubber Sleeve over the Connection.
3 - Connect Wire (BLACK) to a Terminal on an Adjacent Gauge
1 or to Another Suitable Ground.
2
3
72819
1 - Ground (BLack)
2 - Switched 12 Volt Terminal (PURPLE)
3 - Sender Lead (TAN)
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-13
Quicksilver Instrumentation For 454 Magnum EFI Ski
3 4 5
NOTE 1: Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene to connection and
slide rubber sleeve over connection.
NOTE 2: Power for a second fused accessory panel may be tasken from this connection. Load MUST NOT exceed
35-40 amps. Panel ground wire MUST BE connected to instrument terminal that has an 8 gauge black (ground)
harness wire connected to it.
1 - Tachomter
2 - Audio Warning Buzzer (if Equipped)
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
6 - Ignition Switch
7 - To 12 Volt Source (purple wire connection)
8 - 20 Ampere Fuse
INDEX
4D-14 - WIRING DIAGRAMS 90-806535 893
Wiring Diagrams for 502 EFI
A 2
B 3
1 2
c
3
b
2
C
a
71693
A - Audio Warning System C- Charging and Starting System
1 - Oil Pressure Switch 1- Alternator
2 - Drive Unit Oil Level 2- Ground Stud
3- Starter
B- Instrumentation System 4- Circuit Breaker
1- Oil Pressure Sender 5- Starter Slave Solinoid
2- Water Temperature Sender
3- Trim Sender a - Positive Power Wire To EFI System Harness
b - Harness Connector To EFI System Harness
c - Auxiliary Tachometer Lead
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-15
Wiring Diagrams (Continued)
8
4
2
9
11 10 13 20
18
12
5
17
21
19 15
14 16
22
NOTE: All black wires with a ground symbol are interconnected within the EFI system harness. 71692
INJECTORS 2, 3, 5, 8
467 DK BLU
15A INJECTORS 1, 4, 6, 7
15A
30 85 86 87
441 BLU/WHT
IDLE AIR
CONTROL 442 BLU/BLK
(IAC) VALVE 443 GRN/
WHT
444 GRN/BLK
C BLK
INLINE CONNECTOR
(TWIN ENGINE B 916 YEL J1-5 MASTER/SLAVE
APPLICATION ONLY)
A
461 ORN/BLK
TO ECM
FUSE
10A
440 ORN
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-17
EFI Wiring Diagram (2 of 4)
B A
BYPASS
87
15A
ECM BAT FUSE
15A
15A
LANYARD STOP
A
SWITCH CIRCUIT
B BLK
J-1
J-2
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-21
ECM Connector and EFI Symptoms Chart
Pin Pin Circuit Wire Component Normal Voltage Diag- Possible
Func- (CKT) Color Connector nostic Symptoms
ti
tion N
Num- Ignition Engine T bl
Trouble
ber ON Running Codes
(#) DTC(s)
J1-1 Knock 485 BLK Knock 9.5V 9.5V 43 Poor Fuel Economy,
Sensor Sensor Poor Performance
Signal Detonation
J1-2 ECT 410 YEL ECT 1.95V 1.95V 14 Poor Performance,
Signal Sensor (NOTE 2) (NOTE 2) Exhaust Odor,
Rough Idle, RPM Re-
duction
J1-3 Not – – – – – – –
Used
J1–4 Not – – – – – – –
Used
J1-5 Master 916 YEL In Line B+ B+ None Lack Of Data From
Slave Boat Other Engine (Dual
Harness Engine Only)
J1-6 Not – – – – – – –
Used
J1-7 Diag- 451 WHT/ Data Link B+ B+ None Incorrect Idle, Poor
nostic BLK Connector Performance
Test
J1-8 Not – – – – – – –
Used
J1-9 Map 432 LT MAP 4.9V 1.46V 33 Poor Performance,
Signal GRN Sensor (NOTE 3) Surge, Poor Fuel
Economy, Exhaust
Odor
J1-10 TP – DK TP .62V .62V 21 Poor Performance
Signal BLU Sensor (NOTE 4) (NOTE 4) And Acceleration, In-
correct Idle
J1-11 Ignition 439 PNK/ Splice B+ B+ None No Start
Fused BLK
J1-12 Not – – – – – – –
Used
J1-13 TP and 813 BLK TP and IAT 0 0 21,23 High Idle, Rough
IAT Sensor (NOTE 5) (NOTE 5) Idle, Poor Perfor-
Ground mance Exhaust Odor
J1-14 ECM 450 BLK/ Engine 0 0 None No Charge
Ground WHT Block (NOTE 5) (NOTE 5)
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-23
ECM Connector and EFI Symptoms Chart
Pin Pin Circuit Wire Component Normal Voltage Diag- Possible
Func- (CKT) Color Connector nostic Symptoms
ti
tion N
Num- Ignition Engine T bl
Trouble
ber ON Running Codes
(#) DTC(s)
J2-1 Not – – – – – – –
Used
J2-2 Not – – – – – – –
Used
J2-3 Not – – – – – – –
Used
J2-4 Not – – – – – – –
Used
J2-5 Injector 468 LT Injector B+ B+ None Rough Idle, Lack Of
Driver GRN Power, Stall
J2-6 Ignition 463 BLK/ Ignition 0 0 None No Change
Control WHT Control (NOTE 5) (NOTE 5)
Ref. Module
Low
J2-7 Not – – – – – – –
Used
J2-8 Ignition 430 PUR/ Ignition 5V 1.6V None No Restart
Control WHT Control
Ref. Module
High
J2-9 Fuel 465 DK Fuel Pump 0 B+ None No Start
Pump GRN/ Relay (NOTE
Relay WHT 1&5)
Driver
J2-10 Not – – – – – – –
Used
J2-11 Not 112 DK Buzzer, Ig- – – – –
Used GRN niton, Tach
J2-12 Not – – – – – – –
Used
J2-13 IAC ”A” 442 BLU/ IAC Not Not None Rough Unstable or
Low BLK Valve Usable Usable Incorrect Idle
J2-14 IAC ”B” 443 GRN/ IAC Not Not None Rough Unstable or
Low WHT Valve Usable Usable Incorrect Idle
J2-15 Fuel 450 BLK/ Engine 0 0 None No Change
Injector WHT Ground (NOTE 5) (NOTE 5)
Ground
J2-16 Not – – – – – – –
Used
See page 4B-22 for NOTES
INDEX
4D-24 - WIRING DIAGRAMS 90-806535 893
ECM Connector and EFI Symptoms Chart
Pin Pin Circuit Wire Component Normal Voltage Diag- Possible
Func- (CKT) Color Connector nostic Symptoms
ti
tion N
Num- Ignition Engine T bl
Trouble
ber ON Running Codes
(#) DTC(s)
J2-17 Not – – – – – – –
Used
J2-18 Not – – – – – – –
Used
J2-19 Not – – – – – – –
Used
J2-20 Fuel 450 BLK/ Engine 0 0 None No Change
Injector WHT Ground (NOTE 5) (NOTE 5)
Ground
J2-21 Injector 467 DK Injector B+ B+ None Rough Idle, Lack Of
Driver BLU Power, Stalling
J2-22 Not – – – – – – –
Used
J2-23 Ignition 423 WHT Ignition 0 1.2V 42 Stall, Will Restart In
Control Control (NOTE 5) Bypass Mode, Lack
Signal Module Of Power
J2-24 Ignition 424 TAN/ – 0 4.5V 42 Lack Of Power, Fixed
Control BLK (NOTE 5) Timing
Bypass
J2-25 Not – – – – – – –
Used
J2-26 Not – – – – – – –
Used
J2-27 Not – – – – – – –
Used
J2-28 Idle Air 441 BLU/ IAC Valve Not Not None Rough Unstable or
Control WHT Usable Usable Incorrect Idle
”A” High
J2-29 Ilde Air 444 GRN/ IAC Valve Not Not None Rough Unstable or
Control WHT Usable Usable Incorrect Idle
”B” Low
J2-30 Not – – – – – – –
Used
J2-31 Mal- 419 BRN/ Data Link 0 0 None Lamp Inoperative
function WHT Connector (NOTE 5) (NOTE 5)
Indica-
tor
Lamp
J2-32 Not – – – – – – –
Used
See page 4B-22 for NOTES
INDEX
90-806535940 893 WIRING DIAGRAMS - 4D-25