How to: Index the Spark Plugs on a Ficht /
Direct Injection Outboard
Identify the powerhead.
If you’re working on a 60º V6 (150 or 175 hp) which is a 1999 model year or
older motor, the first step you need to take, is to positively identify the
powerhead. In many cases there were numerous updates or, in cases where
customers experienced several powerhead failures OMC may have replaced
the original style powerhead with an updated “full dressed” version. It is
entirely possible to have a 1998 engine with a 2001 design powerhead.
Also, at one point in time there was a lot of confusion regarding spark plugs
for these engines as there were about eight different spark plugs offered. In
March of 2000, OMC produced a service bulletin addressing Ficht spark plugs
and this bulletin simplified spark plug selection. The information in the chart
below was taken from that service bulletin, so don’t be alarmed if the plugs
you take out of your engine don’t match the chart. Keep in mind however, if
the wrong spark plugs are installed in the engine you may experience
running problems which could possibly cause serious, permanent damage to
the engine.
If you have difficulty identifying the engine model year, seek the assistance
of a qualified Evinrude†/Johnson† dealer, they may need to access the
engine’s ECU and read the data stored in the computer’s memory.
Engine Family Model Champion† Plug# Gap
Info
& Horsepower Year (BRP† Part#) Specification
60º V4 - 90, 1998 – 7712 .030”
ALL
115 1999 (5001111) (0,8mm)
60º V4 - 75, 2000 & XC12PEPB .030”
ALL
90, 115 newer (5001211) (0,8mm)
Without
60º V6 - 150, 1997 – pinned 7712 .030”
175 1999 cylinder (5001111) (0,8mm)
heads*
With
60º V6 - 150, 1997 – pinned XC12PEPB .030”
175 1999 cylinder (5001211) (0,8mm)
heads*
60º V6 - 135, 2000 & XC12PEPB .030”
ALL
150, 175 newer (5001211) (0,8mm)
90º V6 - 200, 1999 & QC12PEP .030”
ALL
225, 250 newer (5001866) (0,8mm)
* Note: See next section for explanation and identification.
Revision date: 2/24/2005
What’s a “pinned cylinder head”?
In the evolution process of the Ficht technology, the OMC engineers
discovered they could minimize the build up of soot which occurred on some
engines by adding a “deflector pin” in the combustion chamber. This pin is
placed between the fuel injector and the spark plug electrode and it helps to
keep the spark plugs cleaner, longer and allows the engines to run better. If
you own (or are working on) a 1999 or older 60º V6, compare the following
two pictures to determine which style cylinder head is installed on your
engine, this is very important to assure you purchase and install the correct
spark plugs.
Identification. Cylinder heads are identified by looking at the machined
recess area in which the spark plug is installed. Note: This id process does
not apply to 2000 and newer outboards.
This is a picture of cylinder head
“without pins”, also known as an un-
pinned cylinder head. It is identified
by the “perfect circle” the machined
area produces.
Original design cylinder head
used on 1997/1998 Ficht
150 & 175 hp
This is a picture of cylinder head “with
pins”, also known as a pinned cylinder
head. It is identified by the additional
machined area located aft of the spark
plug.
Notice the “hex-head” at the bottom of
the smaller machined area - this is
the pin.
Note: The 90º V6’s (200 thru 250 hp),
do not use this style of pin. The pin is
actually cast inside the combustion Cylinder head used in
chamber. various “upgrade” kits and
on 2000 & newer models.
Revision date: 2/24/2005
Tools Required.
- A quality torque wrench
(2 types shown)
- A 3/8-drive Ratchet
Wrench
- A 3/8-drive Breaker Bar
(optional)
- A Sharpie† Pen
- 5/8” Spark Plug Socket
- Socket Extensions
(optional, but handy)
- Universal Joint
(optional, but handy)
- A Spark Plug Gapping Tool
(3 types shown)
Preparing the Spark Plugs.
The first step is to set the spark
plug gap to the specification. All of
the factory service literature Gap = .030”
specifies a gap of .030”. But it is (0, 8mm)
commonly accepted to set the plug
gap to .028”
Use your spark plug gap tool to
measure and adjust the gap as
necessary. Bend the spark plug “J”
electrode at its bend (see arrow,
right) to adjust the gap.
Next, you will need to use a Sharpie† pen (or other fine point marker) to
draw a reference mark on the ceramic portion of the spark plug.
Draw the reference mark in Open end of electrode
line with the open end of
the spark plug’s electrode.
Revision date: 2/24/2005
Installing and Indexing.
Be sure to read the note on
torque specs below, before you
begin this task.
Install a spark plug in a cylinder.
Using your torque wrench and spark Zone “A”
plug socket, torque the spark plug to
15 ft-lbs (or 20 N-m).
- If the indexing mark you drew on
the ceramic portion of the plug is in Index Line
zone B, you’re done with this
cylinder.
- If the index mark is in zone A Zone “C”
(see arrow, right), reset the torque Zone “B”
wrench to 30 ft-lbs (or 41 N-m) and
continue torqueing until either the Port cylinder bank shown
mark aligns with the pin (injector),
or until the torque specification is
met (which ever comes first).
- If the index mark is in zone C, this spark plug will not work in this
cylinder, try another spark plug in this location.
NEVER use a shim to index the spark plugs!
The port cylinder bank is illustrated, the index line and zones will be
“mirror-reversed” when you do the starboard cylinder bank.
A note about the torque specs: The earliest literature regarding spark
plug indexing appeared in the cylinder head upgrade kits OMC offered for
the 1998 model 150/175 hp V6’s. It specified an initial torque of 12 ft-lbs
and a final torque of 22 ft-lbs. OMC eventually revised the initial torque to
15 ft-lbs. These specifications have been revised by BRP and I’ve used the
specs from the 2002/2003 service manual for this article and, they are
acceptable for all Ficht/DI motors. You may find older service literature that
does not agree with the new specs. Lastly, keep in mind the 30 ft-lbs final
torque spec is what the factory uses so that assembly workers don’t waste
time replacing plugs. Those of us who regularly service these engines rarely
exceed a final torque of 22 ft-lbs. When spark plugs are torqued to 30 ft-
lbs, you risk breaking the plug, either during installation, or in the future
when its time to replace it.
-JG
† Evinrude, Johnson and BRP are Registered trademarks of Bomardier Recreational Pruducts, U.S. Inc.
Champion is a registered trademark of Federal Mogul Corp and Sharpie is a registered trademark of Sanford Corp.
Revision date: 2/24/2005
