Spark plug wire procedures for 2001 2002 2003 2004 2005 and 2006 MerCruisers inboards. Note, procedures may differ depending on year and model. See repair manual for additional instructions and pictures for additional repair procedures.
Models Covered in This Manual
Sterndrive (MCM)
5.0L MPI Alpha and Bravo
350 5.7L MAG MPI Alpha and Bravo
350 5.7 L MAG MPI Alpha and Bravo Horizon
MX 6.2 MPI
MX 6.2 MPI Horizon
Inboard and Tow Sports (MIE)
350 MAG MPI Inboard
350 MAG MPI Horizon Inboard
MX 6.2 MPI Inboard
MX 6.2 MPI Horizon Inboard
350 MAG MPI Tow Sports
SPARK PLUG WIRES
1. Examine both the coil and spark plug wires for signs of damage by looking at them.
2. Examine spark plug boots for signs of damage by looking at them as well.
Tip: Be careful when removing the spark plug wires and the boots. To remove them, turn the boot one half turn. Then, with a firm grip, grab the boot and pull. This will expose the wire.
3. Using a digital meter, check for continuity in the spark plug wires and coil wire. If a wire fails to show complete continuity, it must be replaced.
4. All damaged wires must be replaced.
CAUTION: Only use marine application recommended spark plug wires.
Tip: To reduce errors, replace spark plug wires one by one.
5. Each spark plug wire should be disconnected alone.
6. The new wires need to be installed in order.
IMPORTANT: The wires must be routed properly through the correct supports. The wires have to be routed correctly to ensure that there is no cross firing.
a. Place each wire in the supports and retainers.
b. On the distributor cap, connect the wires to the appropriate plug and terminal. They should have a safe fit.
IMPORTANT: Apply one half ounce of silicone dielectric compound to the top of the coil high tension lead tower. Do not put the compound inside of the tower hole. Make sure to apply the compound before proceeding with installation of the coil wire.
c. Now, the coil high tension lead tower needs to be sealed. Connect the coil wire to the distributor cap by attaching it to the center terminal.
Tip: For the coil on the high tension lead tower, use Silicone Dielectric Compound, part number 92-823506-1
d. The end of the high tension wire needs to be pushed in to the coil tower. The boot should be positioned over the coil tower. Remove any leftover insulating compound.
Make sure that hydraulic air pressure that is inside of the boot does not force the boot to be separated from the tower.
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