Phase 4 Mercury Marine Confidential 8.2 MAG

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Mercury Marine
New & Current Product ACTIONS
MerCruiser Product
Accurate Customer Targets Integrating OEM/Mercury New Systems
Q3-2012
Mercury Marine Confidential
HPPD Phases of Product Development
•
As a project proceeds through its implementation phases, the following activities will be completed.
•
Phase 2 SELECT CONCEPT (6 – 18 months before SOP)
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–
•
Phase 3 DESIGN FREEZE (4 – 12 months before SOP)
–
–
–
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•
Coordinate Design Validation build at boat builders (with 3-D CAD models and/or hardware)
Document integration issues surfaced during DV build
Develop and implement an "Integration Specifications Page" which captures all issues which will cause the boat builder to
change their boat or processes.
Coordinate with the appropriate individuals to update Installation Process FMEA's
Phase 4 PREPARE FOR PRODUCTION (2 – 6 months before SOP)
–
–
–
•
Coordinate concept build at boat builder (with 3-D CAD models and/or hardware)
Document integration issues surfaced during the concept builds.
Develop joint OEM/Mercury Validation Plan
Communicate this information to the PAE's and determine other issues missed.
Inform team of issues and work to develop resolution.
Validate resolution with selected boat builder and PAE's
Develop action plans (fit/function, training, etc) to prepare the builder for the upcoming changes
Facilitate implementation of the action plans
Update the Applications Manuals and Audit Sheets
Phase 5 BEGIN PRODUCTION (1 – 3 months before SOP)
–
–
Coordinate Production Validation builds at builders.
Coordinate Validation testing at builders as needed
Phase #
Mercury Marine Confidential
Table of Contents
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MerCruiser Sterndrive Product Lineup – 2012 Program Year………………………………………......
Engine and Drive Weights……………………………………………………………………………..............
Engine Installation – Parts Bags………………………………………………………………………………
Master Parts Bags………………………………………………………………………………………….........
Boxing Line Summary – Scan Items………………………………………………………………...............
TKS Oil Drain Bilge Plug / Tether………………………………………………………………………..........
Oil Pressure (Analog) Change……………………………………………………………….........................
Paint Changes – Components ………………………………………………………………………………...
Oil Pan Plug Removed – TKS…………………………………………………………………......................
8.2L MIE Exhaust Diverters (Stage 1)……………………………………………………………….............
Service Bulletin List…………………………………………………………………………………................
8.2 MAG- Generation II …………………………………………………………………………………………
Throttle Body Silencer …………………………………………………………………………………………
8.2L Exhaust Changes …………………………………………………………………………………………
8.2 MAG Non EC Changes …………………………………………………………………………………….
3-Serial Number Decals ………………………………………………………………………………………..
Hot Stud on Small Blocks ……………………………………………………………………………………..
Refreshed 4500 Single Console Control …………………………………………………………………....
OBDM MIL Light – ECT Only …………………………………………………………………………............
IQ EOL Sheets – New fax number ……………………………………………………………………………
Mercury P.I.E. Website …………………………………………………………………………......................
Mercury Marine Website…………………………………………………………………………....................
Items with updates are highlighted in BLUE Text
Phase #
Mercury Marine Confidential
4
5
6
7
8
9
10
11
12
13
14
15
24
25
28
29
30
31
32
33
34
35
Sterndrive Product Line Up - 2012
STERNDRIVE PRODUCT LINE UP
2012 Program Year
All USA
HP
July - December
2011
January - July
2012
All Canada
July - December
2011
January - July
2012
All Other Countries
July - December
2011
January - July
2012
3.0L
135
3.0L
3.0L
3.0L
4.3L
190
4.3L
4.3L
4.3L
3.0L MPI Catalyst
135
3.0L MPI ECT
3.0L MPI ECT
4.3L MPI
220
4.3L MPI
4.3L MPI
4.3L MPI Catalyst
220
4.3L MPI ECT
4.3L MPI ECT
5.0L MPI
260
5.0L MPI
5.0L MPI
5.0L MPI Catalyst
260
5.0L MPI ECT
5.0L MPI ECT
350 MAG
300
350 MAG
350 MAG
350 MAG Catalyst
300
350 MAG ECT
350 MAG ECT
377 MAG
320
377 MAG
377 MAG
377 MAG Catalyst
320
377 MAG ECT
377 MAG ECT
8.2 MAG
380
8.2 MAG
8.2 MAG
8.2 MAG Catalyst
380
8.2 MAG ECT
8.2 MAG ECT
8.2 MAG HO DTS
430
8.2 MAG HO DTS
8.2 MAG HO DTS
8.2 MAG HO ECT
8.2 MAG HO ECT
8.2 MAG HO Catalyst 430
3.0L MPI ECT
3.0L MPI ECT
4.3L MPI ECT
4.3L MPI ECT
3.0L MPI ECT
3.0L MPI ECT
4.3L MPI
4.3L MPI ECT
4.3L MPI ECT
5.0L MPI
5.0L MPI ECT
5.0L MPI ECT
5.0L MPI ECT
5.0L MPI ECT
350 MAG
350 MAG ECT
350 MAG ECT
350 MAG ECT
350 MAG ECT
377 MAG
377 MAG ECT
377 MAG ECT
377 MAG ECT
377 MAG ECT
8.2 MAG
8.2 MAG ECT
8.2 MAG ECT
8.2 MAG ECT
8.2 MAG ECT
8.2 MAG HO DTS
8.2 MAG HO ECT
8.2 MAG HO ECT
8.2 MAG HO ECT
8.2 MAG HO ECT
ECT = Emission Control Technology (Catalyst)
Information is subject to change, call Mercury for the latest updates.
Phase 5
Mercury Marine Confidential
Engine and Drive Weights
MerCruiser NON-EC
Engine Weights
MerCruiser EC
Engine Weights
3.0L
3.0L
455
3.0L
3.0L EC
4.3L
Drive Weights
Alpha Transom
79
95
515
60
Alpha Drive
775
50
Bravo Transom 90
4.3L
725
4.3L
Weight
Change*
Small Block
4.3L EC
Small Block
Bravo 1 Drive
142
5.0 MPI
815
5.0 EC
885
70
Bravo 2 Drive
157
350 MAG
815
350 MAG EC
885
70
Bravo 3 Drive
167
377 MAG
815
377 MAG EC
885
70
Big Block
Big Block
8.2 NON EC
990
8.2 MAG EC
1122
*All weights are engine only, all weights in pounds (lbs)
0" risers on everything but 8.2 - 2" risers
Phase 5
132
Mercury Marine Confidential
Engine Installation – Parts Bags
• Project Definition
A project is in place to mitigate parts bag issues / incorrect parts. A scanning
process along with a pick-light system has been implemented to ensure that
correct parts are being shipped.
– Benefits
– Mitigate missing / incorrect parts
– Reduce effort / time spent obtaining parts and reporting failures
– Eliminate manufacturing line-down time losses
– OEM Impact
Parts bags will be packaged as they are today with two additional items
if applicable (clean power harness and the power steering fluid).
See following slides for greater detail.
SOP – Scanning (7/9/2012)
SOP – New Parts Bags (7/30/2012)
Phase 4
Mercury Marine Confidential
“Master” Parts Bags
• New Bag Assemblies
– Supplier Sourced Bag Assemblies
– 13 Bags (Sterndrive)
– 11 Bags (MIE / SKI)
• MIE / SKI bags are all-inclusive
(Parts and Owners Literature)
• Each bag will have a part number / bar
code for scanning purposes
(Accuracy)
• Added Components
–
Power Steering Fluid
•
–
Removed from loose location on engine
– now in the master bag.
Clean Power Harness
•
Removed from its individual location on
the rear of the engine – now in the
master bag.
Phase 4
Mercury Marine Confidential
Boxing Line Summary – Scan Items
• 13 MCM Bags
• 11 MIE Bags
• 9 MCM Owners
Manual Packets
• 7 Transom Harness
Assemblies
• 4 Transom
Assemblies
• 8.2L Air Silencer
Phase 4
• 1 Pint Gear Lube Bottle
(8.2L Stage II)
• Fuel Filter Assembly
– (MIE)
• Power Steering
Cylinder
– (Black X - Current)
• Coolant Reservoir
– (SB FWC Engines)
• Trim Pump
Mercury Marine Confidential
TKS Oil Drain Bilge Plug / Tether
• The TKS (3.0L and
4.3L) bilge plug/tether
has been removed
from the parts bag
and placed directly on
the engine.
• 4.3L
• 3.0L
• SOP – June 2012
Phase 4
Mercury Marine Confidential
Oil Pressure (Analog) Change
Project Definition
In order to enhance quality / component
design, a supplier change is being validated
to replace the current (old) sender.
Old
New
•Benefits
• Mitigate oil pressure sender failures
• Greater gauge accuracy
• Reduce overall warranty
•OEM Impact
• Reduce EOL failures
• Mitigate replacements / labor
* Note – These are painted black on the engine.
•SOP – Single Wiper – April 2012
•SOP – Dual Wiper – August 2012
Phase 4
Mercury Marine Confidential
Paint Changes - Components
• 8.2L Fuel Rail
– Removed the rail prior to paint due to hose degradation
(Service Bulletin 2012-05)
– SOP – February 2012 SNB – 2A030176
• O2 Sensors
– Removed the O2 Sensors prior
to paint due to water intrusion
and wire breakage.
SOP – April 2012 SNB – 2A034976
Unpainted O2
Sensor
Unpainted 8.2L
Fuel Rail
Phase 5
Mercury Marine Confidential
Oil Pan Plug Removed - TKS
Project Definition
•
Remove the actual oil pan plug from the parts bag on all TKS engine packages (3.0L
and 4.3L engines). No longer providing this plug as the VOC has suggested that it is
not used at the dealer / end-user level.
Benefits:
• N/a
OEM Impact:
• N/a
•
SOP – May 2012
Phase 5
Mercury Marine Confidential
8.2L MIE Exhaust Diverters
(Stage 1)
• With the implementation of the new 8.2L (Stage 2), the
exhaust diverter tubes will no longer be necessary.
• Stage 2 “Starting” Serial Number – 2A041665
Phase 4
Mercury Marine Confidential
Service Bulletin List
• 2012 Service Bulletin List (to date)
Phase 5
Mercury Marine Confidential
8.2 MAG – Generation II
Phase 4
Mercury Marine Confidential
8.2 MAG – Generation II
Throttle Body Silencer - Packaging
Project Definition:
•Protect Plastic silencer-shipping
•Installation Protection
•On engine – Not in box
•OEM Impact:
•Remove Prior to Installing Engine (leave
foam attached for added protection)
•Remove if using plenum for alignment
•Remove foam before running the engine
Phase 4
Mercury Marine Confidential
8.2 MAG – Generation II
Standard Equipment and Features (used on 100% of all models):
-- Closed Cooled
-- Engine Oil Cooler
-- Air Actuated Drain
-- Stainless Ground Studs
-- Remote Oil
-- Oil Evacuation Feature on Dipstick Tube
Notes:
-- There is no 8.2 MAG Stage 2, Non ECT derivative required. Non ECT models will continue to be sold as is (legacy exhaust system).
-- All models will be equipped only with digital sensors, like existing 8.2 models
-- SeaCore quality hardware is to be used throughout, except for the engine mounts, like existing 8.2 models
-- The Horizon Inboard models are analogous to the SeaCore MCM models (SS mounts and model specific graphics)
-- Only the MCM SeaCore model will receive an engine flush system, and this will be a running engine flush.
Sterndrive (MCM) Model Options:
•
380 HP (HO)
•
430 HP (HO)
•
Mechanical throttle and shift
•
Digital Throttle and Shift (DTS)
•
Power Assisted Steering (on 100% of the MCM models)
•
SeaCore
•
•
•
•
•
•
Inboard (MIE) Model Options:
• 375 HP (Base)
• 425 HP (HO)
• DTS only. No mechanical throttle and shift Inboards.
• V-Drive and Down angle transmissions only
Specifically, ZF 63IV, ZF 63A, and ZF 80A transmissions.
• Horizon (SS front mounts + graphics)
(standard MCM engine + running engine flush, SS front mounts, and
graphics package)
• 1 central dipstick at front of engine, or Dual dipsticks (to
facilitate access in the various installations)
Axius [SeaCore content (SS front mounts) + graphics]
• Shaft log cooling water port (100% MIE’s)
MerCathode (on 100% of the MCM models)
• 50 mm Risers (aka 2 in)
Hot Stud
• 100 mm Risers (aka 4 in)
50 mm Risers (aka 2 in)
100 mm Risers (aka 4 in)
• 150 mm Risers (aka 6 in)
150 mm Risers (aka 6 in)
** Min exhaust height above waterline = 380 mm (15 in)
** Min exhaust height above waterline = 330 mm (13 in)
Phase 4
Mercury Marine Confidential
Project Definition
• 8.2 MAG Stage 2
8.2 MAG – Generation II
– New Exhaust Manifolds/Elbows
– Single Catalyst/side
– Larger Drive Lube Bottle
– New Remote Oil Filter Adapter
– Redesigned Power Steering Reservoir
– Shift Plate Relocation
•Benefits
• Same Envelope as previous exhaust
• Larger Drive Lube Bottle
• Bullhorn and Intermediate elbows installed at Factory
• Lower CO exhaust emissions than the previous version
•OEM Impact
• Only offer 2”, 4” and 6” elbows (0” and 8” NLA)
• 37 lbs. heavier than current production
• Extra Bottle of Drive Lube (1 Pint) with engine for larger Reservoir.
• SOP: July 11, 2012 1st Serial number: 2A041665
Phase 4
Mercury Marine Confidential
8.2 MAG – Generation II
New Part Numbers for Stage 2
Sterndrive (MCM)
Old Model # New Model #
Description
Inboard (MIE)
Old Model # New Model #
Description
40820001U
40820001V
8.2 Mag HO EC 2R D07 EO
30820003U
30820003V
HZ 8.2 EC 2R D07 63V 2.00:1
40820002U
40820002V
8.2 MAG EC 2R
30820008U
30820008V
HZ 8.2 EC 2R D07 63A 1:50:1
40820003U
40820003V
8.2 MAG EC 6R D07
30820018V
HZ 8.2 EC 6R D07 63V 2.5:1
40820004U
40820004V
8.2 MAG HO EC 2R
30820012U
30820012V
8.2 HO EC 6R D07 63A 2.7:1
40820007U
40820007V
8.2 Mag HO EC 2R D07
30820014U
30820014V
8.2 HO EC 2R D07 63A 1.50:1
40820010U
40820010V
8.2 Mag EC 2R D07
30820015U
30820015V
8.2 HO EC 6R D07 63A BOB
40820011U
40820011V
8.2 MAG EC 4R D07
40820013U
40820013V
8.2 MAG EC 2R EO
40820014U
40820014V
8.2 Mag HO EC 2R EO
40820015U
40820015V
8.2 MAG HO EC 6R D07
40820016U
40820016V
8.2 MAG EC 4R
40820022U
40820022V
8.2 MAG HO EC 4R D07
40820024U
40820024V
8.2 Mag EC 2R D07 SEA
40820025U
40820025V
SEA 8.2 MAG EC 4R D07
40820029u
40820029V
8.2 Mag EC 6R
40820030U
40820030V
SEA 8.2 MAG HO EC 2R D07
40820034U
40820034V
SEA 8.2 MAG 2R D07
40820035U
40820035V
8.2 Non-Cat Mag HO 2R D07
40820041U
40820041V
8.2 MAG 2R D07
40820042U
40820042V
8.2 MAG 6R D07
40820044U
40820044V
8.2 MAG 2R
40820045U
40820045V
8.2 MAG 6R
40820047U
40820047V
SEA 8.2 MAG HO EC 4R D07
40820055U
40820055V
SEA 8.2 MAG 2R
40820056U
40820056V
8.2 MAG 2R EO
Phase 4
Mercury Marine Confidential
8.2 MAG – Generation II
• ECT New Spec Decal Location
•Spec Decal
–Location change
–On coolant reservoir
•Larger text is easier to read
•QR Code
•ECI (Emissions) decal remains
on heat exchanger
Phase 4
Mercury Marine Confidential
8.2 MAG – Generation II
Maintenance Monitor
• Implemented an engine
oil life indicator as shown.
– Oil change and
maintenance required
1 year
– This is common with
the new 150 OB
Phase 4
Mercury Marine Confidential
8.2 MAG – Generation II
• OEM Emissions Probe Access
Phase 4
Mercury Marine Confidential
8.2 MAG – Generation II
Risers:
2” Factory Standard
4” Option
6” Option
Intermediates:
Included w/ engine
Bullhorn (Y-pipe):
Included w/ engine
Phase 4
Mercury Marine Confidential
Throttle Body Silencer
Rubber Grommet X2
Paint on the Silencer
To match Plenum
•
•
Big Block DECAL
Silencer Features
– Noise Reduction
• 2500 - 4700 Cruise to
WOT RPM
• 2 DB reduction
average
– Grill styling
– Big Block V8 decal
– Easy removal
• Push on rubber
grommet design
Service Back-Fit Kit for Current
8.2 Models
– PN 8M0063432
BRACKET
Rubber Grommet X2
DTS and Mechanical
are different brackets.
•Standard on all Sterndrive and MIE
•Not installed on V-drive ( * rear facing engine)
Phase 4
Mercury Marine Confidential
8.2L Exhaust Changes
Intermediate Elbow Closer to Transom 1.1”
Will have a “Cobra” looks (flat and wide)
2” Riser
4” riser, same setback as above.
Phase 4
Mercury Marine Confidential
Elbow Outlet Length Comparison
Original Elbow Outlet Length
Phase 4
New Design: + 64 mm Elbow Outlet Length
Mercury Marine Confidential
Exhaust Outlet Dimensions
Big Block Exhaust - Outlet Dimensional Comparison
H
0 in (0 mm) Risers
2 in (50.8 mm) Risers
4 in (101.6 mm) Risers
6 in (152.4 mm) Risers
8 in (203.2 mm) Risers
REFERENCE:
Current Production 8.2L EC
Intermed.
EXH H
W
Elbow P/N
*
24.25 (616)*
26 (660)**
28 (711)**
30 (762)**
24.25 (616)
Next Generation 8.2L EC Exhaust (June 2012 SOP)
Intermed.
H
EXH H
W
Elbow P/N
18.5 (470) 13.9 (353) 8M2018450
N/A
N/A
N/A
N/A
21.2 (538) 13.9 (353) 8M2018452
20.8 (529)
12.8 (325)
8M2020356
22.8 (580)
12.8 (325)
8M2023529
25.2 (640) 13.9 (353) 8M2018456
*
26.2 (665)**
28.2 (716)**
24.8 (631)
12.8 (325)
8M2023530
27.1 (688) 13.9 (353) 8M2018458
N/A
N/A
N/A
N/A
23.2 (592) 13.9 (353) 8M2018454
24.25 (616)
General Notes:
1. Refer to the complete engine illustrations below to see the features that the dimensions in the table refer to.
2. See detail image below for a comparison of the exhaust system length; current production vs new engine
3.
4.
* Package height determined by the top of the plenum or engine cover.
** Package height determined by the top of the exhuast elbow.
8.2 Non-ECT with 2 in.
Risers
Phase 4
Mercury Marine Confidential
8.2 MAG Non EC Changes
•Front lift bracket to be changed out at
pre-dress to keep long block common
with new EC 8.2
•Common with Stage 2 EC: Coolant
reservoir, drive lube reservoir, dipstick
tube, plus some hoses and brackets.
•Single dipstick variant to inventory on
the line.
•Common Oil Cooler for EC and Non
EC version
•Single harness between stage 2
MCM EC and Non EC.
•Remove starboard side “L” bracket
and hardware.
•SOP – JULY 9 2012
Phase 4
Mercury Marine Confidential
3-Serial Number Decals
INFORMATIONAL ONLY:
1AXXXXXX Serial Numbers:
These decals used to be taped to the
Back of the engine.
2AXXXXXX Serial Numbers:
They are now put in the literature bag.
Phase 5
Mercury Marine Confidential
Hot Stud on Small Blocks
Project Definition
Simplified installation of positive battery cable to a
very accessible hot stud with protective boot.
•Benefits
• Easy positive battery installation while in boat
• No interaction with starter solenoid
•OEM Impact
•If Batteries are located in back of engine bay,
positive battery cables could be shorter,
potential cost savings
•NOTE: Inboards do not have a hot stud due
to top mounted starters.
•SOP – Q4 2012
Phase 3
Mercury Marine Confidential
Refreshed 4500 Single Console
Phase 5
Mercury Marine Confidential
OBDM – MIL Light – ECT ONLY
• This is the tag that will hang from the OBDM
MIL Light Connector on back of engine.
Serial Number
Date
1A648623
1A352946
1A092818
5/16/2011
5/16/2011
5/16/2011
Reason
MIL Light on 3.0L, 4.3L, 5.0L, 350 MAG and 377 MAG MCM
MIL Light on 8.2 (all)
MIL Light on small block MIE
Phase 5
Group
Mil Light Calibration
Mercury Marine Confidential
IQ – EOL Sheets – New Fax #
New EOL (End Of Line) test sheets available:
www.mercurypie.com
Location:
Shared Files
IQ Certification Documents
One Page EOL Test – Flush Device 09-28-10.pdf
One Page EOL Test – In Water 09-28-10.pdf
NOTICE: Fax number changed!!!
Phase 5
Mercury Marine Confidential
P.I.E. - Website
• Project Definition
– A website for OEM’s to use as
a central point for information
from Mercury Product
Integration Engineering
www.mercurypie.com
• Benefits
– Links to helpful information
•
•
•
•
•
ACTION Presentations
Catalyst Information
Architecture Drawings
Installation Sheets
User Manuals
• OEM Impact
– To receive a user name &
password, click “Contact Us”
and fill out, you will receive a
login by e-mail.
Phase 5
Mercury Marine Confidential
Mercury Marine Website
•
Project Definition
– Develop a new website that is more
interactive and friendlier to use
http://www.mercurymarine.com
•
•
Benefits
– Streaming video and information
over the latest products from
Mercury
– Links to FAQ’s, Technical
Information, Product Literature
OEM Impact
– Dedicated sections to:
•
•
•
•
•
SmartCraft/DTS
Engine Families
Propellers
Performance Data
Find a Dealer
Phase 5
Mercury Marine Confidential
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