Marine Power 5.3 GEN V DI Manuel utilisateur

4.3L/5.3L/6.2L/LT4

MEFI 7 DIRECT INJECTION

ENGINE OWNER’S MANUAL

VERSION 4

i www.MarinePowerUSA.com

Table of Contents

Section 1: introduction

ProPosition 65......................................................................1

safety Warnings ....................................................................1

rePlacement Parts...................................................................1

safe Boating .........................................................................2

Warranty ..........................................................................2-6

Section 2: Safe Boating

carBon monoxide exPosure........................................................6

Section 3: engine identification

engine tyPe...........................................................................7

model sPecifications................................................................8

Section 4: electronic Sequential fuel injection

information ............................................................................9

Section 5: engine alarmS and inStrumentation

digital alarms......................................................................10

instrumentation ....................................................................11

Section 6: SSVec fuSe and relay encloSure ......................12-15

Section 7: PrecautionS

oil level ............................................................................16

Hydrolock ..........................................................................16

Section 8: engine oPerating inStructionS

gasoline requirements............................................................17

oil requirements ..................................................................17

starting engine efi...............................................................17

engine Break-in/25 Hour insPection.....................................17-18

Section 9: Winterization

4.3/5.7l raW Water cooled engines .......................................19

full closed cooled engines .....................................................20

Half closed cooled engines................................................21-22

full closed inBoard Jet engines ................................................23

Section 10: engine maintenance

scHeduled maintenance By oWner ..............................................24

scHeduled maintenance By qualified tecHnician...............................25

crankcase oil cHange.............................................................26

oil filters ..........................................................................27

flame arrestor ....................................................................28

g-force fuel system .............................................................28

Battery caBles .....................................................................29

multiPle engine Battery Precautions - efi ....................................29

alternator Belt tension ..........................................................29

sea Water PumP imPeller rePlacement.........................................29

closed cooling system...........................................................30

filling closed cooling system .............................................30-31

Section 11: engine diagnoSticS and codeS ........................32-34

Section 12: trouBle Shooting

engine Will not turn over .....................................................35

engine cranks But Will not start.............................................35

engine runs Poorly at HigH rPm..............................................36

HigH sPeed miss ..................................................................36

fuel system - ricH ................................................................37

fuel system - lean................................................................37

Poor fuel economy ...............................................................37

engine starts and stoPs .........................................................38

oil Pressure - loW................................................................38

oil Pressure - HigH ...............................................................38

excessive oil consumPtion.......................................................39

engine overHeating................................................................39

Water in engine cylinder or Base ..............................................40

Section 13: inStallation inStructionS

engine comPartment...............................................................41

engine mounting ..................................................................41

engine rotation ....................................................................41

engine Bed..........................................................................41

cooling system...............................................................41-42

emission-related installation instructions.....................................42

exHaust PiPing ................................................................42-43

electrical connection .............................................................43

Batteries ............................................................................43

dual engines .......................................................................43

Battery isolators ..................................................................43

engine Battery sPecifications ....................................................44

Battery caBle lengtH requirements.............................................44

sPecial fuel instructions for 6.2 550 HP engines........................44

lsa airBoat installation notes .................................................45

adaPter Harness...................................................................46

Heater connections ...............................................................47

Prestart cHecklist .................................................................48

Potentiometer oPeration..........................................................49

Warranty regiStration tranSfer .............................................50

SerVice log......................................................................51-53

1www.MarinePowerUSA.com

DANGER

WARNING

CAUTION

DANGER

WARNING

CAUTION

DANGER

WARNING

CAUTION

1. Introduction

Marine Power would like to thank you again for your pur-

chase. The pleasure and peace of mind derived from your new

engine is in direct proportion to the amount of care that it is

given. We have tried to include as much as possible in our Engine

Owner’s Manual to help you as the customer. READ THIS

MANUAL THOROUGHLY AND COMPLETELY before attempting

to operate your Marine Power engine. We ask that you become

familiar with the components and the maintenance schedules. If

you have any questions or concerns regarding this manual or your

newly purchased Marine Power engine, please feel free contact

your nearest Marine Power dealer or distributor.

Proposition 65

“Safety Warnings” and additional information or instructions are

used to alert the installer/operator of possible safety hazards in

performing certain service or maintenance procedures incorrectly

or carelessly.

These “Safety Warnings” alone cannot eliminate the hazards

that they signal. Strict compliance with these warning instruc-

tions while performing service and maintenance procedures,

plus “common sense” operation, are major accident prevention

measures.

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm. The LT4 Is a Premium 93 Octane REQUIRED engine. The

engine will operate at significantly reduced power output with

octane levels down to 90. Operating the LT4 on fuel below

90 Octane can result in engine damage and or failure! Such

failure will not be covered under warranty!

Electrical, ignition and fuel system components are designed

and manufactured to comply with U.S. Coast Guard rules and

regulations to minimize the possibility of fire or explosion

hazard.

Safety Warnings

Signals serious damage, failure or breakdown of equipment;

severe injury or high probability of death to the user if proper

precautions are not taken. This signal word is applied in extreme

situations.

Indicates a potential hazard which could result in personal injury.

Indicates a hazard which could result in damage to equipment.

Replacement Parts

Use of replacement parts (i.e. automotive, after-market, etc.) in the

electrical, ignition and fuel systems, which are not U.S. Coast Guard

approved, could cause a fire or explosion hazard and must be avoided.

Always request that genuine Marine Power engine replacement

parts be used in any repairs or maintenance being performed on

your engine(s).

DANGER

WARNING

CAUTION

DANGER

WARNING

CAUTION

DANGER

WARNING

CAUTION

2www.MarinePowerUSA.com

1. Introduction

Safe Boating

The waterways are becoming increasingly crowded and, in order

to enjoy them safely, the operator should acquaint himself/her-

self with safe boating practices. Boating safely and seamanship

ourses are offered by the following national and state organi-

zations:

• Power Squadrons

• Coast Guard Auxiliary

• Red Cross

• State, provincial or local agencies in charge of water safety

enforcement

Marine Power recommends that all power boat operators attend

one of these courses.

To help locate a course being offered near you, contact Boat

U.S. Foundation’s toll-free national boating safety hotline,

1-800-336-BOAT, and in Virginia, 1-800-245-BOAT.

The Federal Boat Safety Act of 1971 requires that registration of

marine products sold in the United States be maintained by the

manufacturer and dealers of those products. It is imperative that

Marine Power Holding LLC receive your WARRANTY REGISTRA-

TION/SEA TRIAL form properly completed for warranty purpos-

es and to comply with federal regulation. This registration also

enables us to contact you, if it should become necessary, to change

or improve the product for your protection.

WARRANTY REGISTRATION MUST BE RECEIVED WITHIN 10

DAYS AFTER DATE OF PURCHASE BY FIRST OWNER.

Please read the Limited Warranty document that is included

with your engine registration papers and in this manual. This

document explains your warranty coverage. Please note that no

warranty repairs are to be performed without prior authorization

from the Marine Power Distributor in your area. Contact your

selling dealer directly for any required warranty repairs.

For more information, you may also visit our web site at

www.marinepowerusa.com.

Again, thanks for choosing Marine Power.

CALIFORNIA AND U.S. ENVIRONMENTAL PROTECTION AGENCY

EMISSIONS CONTROL WARRANTY STATEMENT

Your Warranty Rights and Obligations

The California Air Resources Board, U.S. E.P.A., and Marine Power

Holding LLC are pleased to explain the emission control system war-

ranty on your inboard engine. New Inboard engines must be designed,

built and equipped to meet California and EPA’s stringent anti-smog

standards. Marine Power Holding LLC must warrant the emission control

system on your Inboard engine for the periods of time listed on the next

page, provided there has been no abuse, neglect or improper mainte-

nance of your inboard engine.

Your emission control system may include parts such as fuel

injection system, the ignition system and catalytic converter. Also

included may be hoses, belts, connectors and other emission-

related assemblies.

Where a warrantable condition exists, Marine Power Holding LLC will

repair your inboard engine at no cost to you, including diagnosis, parts

and labor.

3www.MarinePowerUSA.com

1. Introduction

Manufacturer’s Warranty Coverage

THIS AGREEMENT GIVES YOU SPECIFIC LEGAL RIGHTS, AND

YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM JURIS-

DICTION TO JURISDICTION.

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRAN-

TIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE APPRO-

PRIATE WARRANTY PERIOD IN THE ABOVE TABLE, OR TO THE

EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED

WARRANTIES ARE EXCLUDED. LIABILITY FOR INCIDENTAL OR

CONSEQUENTIAL DAMAGES ARE EXCLUDED TO THE EXTENT

EXCLUSION IS PERMITTED BY LAW. Some states or countries do

not allow limitations on how long an implied warranty lasts, and

some states or countries do not allow the exclusion or limitation of

incidental or consequential damages, so the above limitation and

exclusion may not apply to you. This warranty gives you specific

legal rights and you may also have other rights which vary from

state to state and country to country.

THE FOREGOING REMEDIES ARE EXCLUSIVE. MARINE POWER

MAKES NO OTHER EXPRESS WARRANTY. MARINE POWER SHALL

IN NO CIRCUMSTANCES BE LIABLE IN CONTRACT, IN TORT OR

OTHERWISE FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL

DAMAGES, WHETHER OR NOT FORESEEABLE. NO EMPLOYEE

OR REPRESENTATIVE OF MARINE POWER IS AUTHORIZED TO

MODIFY THIS WARRANTY, OR MARINE POWER’S STANDARD

WARRANTY FOR ANY PRODUCT.

MARINE POWER DOES NOT AUTHORIZE ANY PERSON TO

CREATE FOR MARINE POWER ANY OBLIGATION OR LIABILI-

TY OTHER THAN THAT STATED IN THE LIMITED WARRANTY.

UNDER NO CIRCUMSTANCES SHALL MARINE POWER BE LIABLE

TO THE CUSTOMER OR ANY OTHER PERSON FOR ANY CONSE-

QUENTIAL, INCIDENTAL, ECONOMIC, DIRECT, INDIRECT, GENER-

AL, OR SPECIAL DAMAGES ARISING OUT OF ANY BREACH OF

WARRANTY, EXPRESSED OR IMPLIED.

Owner’s Warranty Responsibilities

As the Inboard engine owner, you are responsible for the

performance of the required maintenance listed in your own-

er’s manual. Marine Power Holding LLC recommends that you

retain all receipts covering maintenance on your inboard engine,

but Marine Power Holding LLC cannot deny warranty solely for

the lack of receipts or your failure to ensure the performance

of all schedule maintenance. Marine Power highly recommends

that the selling dealer do Warranty Registration along with a

completed Statement of Sea Trial in order to facilitate any

warranty work necessary in the future.

As the Inboard engine owner, you should however be aware that

Marine Power Holding LLC may deny you warranty coverage if

your Inboard engine or part has failed due to abuse, neglect or

improper maintenance or unapproved modifications.

You are responsible for presenting your Inboard engine to a

Marine Power Holding LLC distribution center as soon as a prob-

lem exists. The warranty repairs will be complete within a rea-

sonable amount of time, not to exceed 30 days.

1. Marine Power Holding LLC (“Marine Power”) warrants to

the first owner purchasing at retail and all subsequent own-

Engine Type Power Electronic Mechanical

Rating Components Components

Conventional - OEM Less than or equal to 3 Years or 480 Hours 3 Years or 480 Hours

373 kW (500 HP)

Hi-Performance - OEM Between 373 kW (500 HP) 3 Years or 150 Hours 3 Years or 150 Hours

and 485 kW (650 HP)

Complete Engine Repower Less than or equal to 2 Years or 300 Hours 2 Years or 300 Hours

373 kW (500 HP)

Complete Engine Repower Between 373 kW (500 HP) 1 Year or 150 Hours 1 Years or 150 Hours

and 485 kW (650 HP)

Special Applications All 1 Year or 150 Hours 1 Years or 150 Hours

4www.MarinePowerUSA.com

ers, of every Marine Power Inboard marine engine manufac-

tured after January 1, 2008, that the emissions control devic-

es on Marine Power Inboard marine engines are free from

defects in materials and workmanship when manufactured

and will remain so for the stated period in the above table.

Marine Power warrants that each Marine Power Inboard

marine engine and factory installed accessories designed,

built and equipped with all applicable regulations adopted

by the Air Resources Board pursuant to its authority in Chap-

ters 1 and 2, Part 5, Division 26 of the Health and Safety

Code; and the U. S. Environmental Protection Agency pursu-

ant its authority in Chapter 9 of Title 5 of the U.S. Code to be

free from defects in materials and workmanship that cause

the failure of a warranted part to be identified in all material

respects to that part as described in the engine manufacturer

application for certification.

2. The warranty shall commence, on the date of delivery to

the first retail purchaser or from the date the engine is first

placed in service for demonstration or any other purpose

prior to the sale to the first retail owner. However, in no event

shall the duration of this warranty exceed three (3) years

measured from the original retail sale date.

3. Any warranted part that is not scheduled for replacement

as required maintenance in the written instructions in the

Owner’s Manual will be warranted for the appropriate

warranty period in the above table. If the part fails during

the period of warranty coverage, the part will be repaired or

replaced by Marine Power at a warranty station. Any such

part repaired or replaced under warranty will be warranted

for the remainder of the period.

4. Any warranted part that is scheduled only for regular inspec-

tion in the written instructions in the Owner’s Manual will be

warranted for the appropriate warranty period in the above

table. A statement in such written instructions to the effect of

“repair and replace as necessary” does not reduce the period

of warranty coverage. Any such part repaired or replaced

under warranty will be warranted for the remaining war-

ranty period.

5. Any warranted part that is scheduled for replacement as

required maintenance in the written instructions in the

Owner’s Manual will be warranted for the period of time

before the first scheduled replacement date for the part. If

the part fails before the first scheduled replacement, the part

will be repaired or replaced by Marine Power at a warranty

station. Any such part repaired or replaced under warranty

will be warranted for the remainder of the period to the first

scheduled replacement point for the part.

6. Repair or replacement of any warranted part under the

warranty provisions of the article will be performed at a

warranty station at no charge to the owner. Warranty services

and repairs will be provided at all Marine Power distribution

centers and trained marine dealers.

7. The engine owner will not be charged for diagnostic labor

that is directly associated with diagnosis of a defective,

emission related warranted part, provided that such

diagnostic work is performed at a warranty station.

8. Marine Power is liable for damages to other engine compo-

nents proximately caused by a failure under warranty of any

warranted part.

9. Throughout the appropriate warranty period in the table

from the previous page Marine Power will maintain a supply

of warranted parts sufficient to meet the expected demands

for such parts.

10. Any replacement part may be used in the performance of

any warranty maintenance or repairs and will be provided

without charge to the owner. Such usage will not reduce

Marine Power’s warranty obligations.

11. Add-on or modified parts, as defined in CCR, Section 1900

(b)(1) and (b)(10), Title 13, that are not exempted by the

Air Resources Board will not be used. The use of any non-

exempted add-on or modified parts by the ultimate purchas-

er will be grounds for disallowing a warranty claim made

in accordance with this article statement. Marine Power will

not be liable under this statement to warranted failures of

warranted parts caused by the use of non-exempted add-on

or modified part.

12. The following parts are covered by this general emissions

warranty statement.

A) Fuel Metering System

1) Fuel Injectors

2) Fuel Pressure Regulator

3) Manifold Absolute Pressure Sensor

4) Throttle Position Sensor

1. Introduction

5www.MarinePowerUSA.com

5) Throttle Body

6) Coolant Temperature Sensor

7) Oxygen Sensors

8) Intake Valves

B) Air Induction System

1) Intake Manifold

2) Air Filter/Flame Arrestor

C) Ignition System

1) Spark Plugs

2) Electronic Ignition System

3) Spark Advance/Retard System

4) Ignition Coil and/or Control Module

5) Ignition Wires

D) Lubrication System

1) Oil Pump and Internal Parts

E) Positive Crankcase Ventilation (PCV) System

1) PCV Valve

2) Oil Filler Cap

F) Exhaust System

1) Exhaust Manifolds and Risers

2) Exhaust Valves

3) Catalysts

G) Miscellaneous Items Used in Above Systems

1) Hoses, Clamps, Fittings, Tubing, Sealing Gaskets

or Devices and Mounting Hardware

2) Pulleys, Belts and Idlers

3) Vacuum, Temperature, Check and Timer Sensitive

Valves and Switches

4) Electronic Controls

13. The repair or replacement of any warranted part otherwise

eligible for coverage under this warranty may be denied

from such warranty coverage if Marine Power demonstrates

that the engine and/or part has been abused, neglected, or

improperly maintained, and that such abuse, neglect, or

improper maintenance was the direct cause of the need for

repair or replacement of the part.

14. This Warranty will not apply to:

A) Use of an accessories or parts not manufactured or sold by

Marine Power.

B) Neglect, failure to follow maintenance schedules,

accident, abnormal operations, misuse, negligence,

improperly maintained, improperly operated or

installed, racing or engine modification. Problems

arising from installation, application, exhaust to engine,

fuel lines to the engine, propping, cooling to the engine

or engine damage due to defective electrical hookups.

C) Rust, corrosion or effects of weather.

D) Water ingestion through exhaust or intake system.

E) Detonation or operation with fuels, oils or lubri-

cants which are not suitable for use with this product.

Detonation causes: Poor fuel quality, overloading of

engine, improper gear or propeller selection, engine

1. Introduction

overheating, excessive back pressure, incorrect ignition

timing, excessive total timing.

F) Reimbursement for: Haul-out, launch, towing, storage

charges, rental charges of any type, inconvenience of

any type, loss of time or income, expense of returning a

Marine Power product to a service facility, towing, lodg-

ing, loss or damage to personal property.

G) Carburetor replacement and labor is limited to mechani-

cal defects only. Replacement does not extend to contam-

inated fuel, varnish or other residues, changes in fuel

mixtures, poor octane fuel or adjustments beyond five (5)

hours of engine operation.

15. Marine Power reserves the right to limit warranty coverage

on engines that have accumulated excessive hours through

commercial use or any other non-typical operation.

Special Applications Warranty

Marine Power Engines that are used in inboard mud boat

applications (“Special Applications”) carry a strict limited war-

ranty. The warranty period applicable to Special Applications

such as inboard mud boat usage, shall carry a limited warranty

period of one (1) year or 150 hours, whichever occurs first. This

warranty shall only cover and be strictly limited to the repair or

replacement of parts located from the flywheel forward. Repair

or replacement of drive plates are specifically not covered. Any

and all transmission warranties must be handled by the transmis-

sion manufacturer directly. Marine Power’s emission warranty

shall not be limited by these specific limitations. This warranty

6www.MarinePowerUSA.com

2. Damages caused by extreme temperatures in the exhaust

system, including, but not limited to any occurrences of fire,

etc.;

3. Damages caused by or are the result of any sudden impact to

the propeller or any other part of the engine or its accesso-

ries;

4. Damages or failure of the damper drive plate.

Carbon Monoxide is a hazardous gas that is produced when items

containing carbon are burned. Items such as, but not limited to; wood, coal,

gasoline, natural gas, propane or oil. Carbon Monoxide (CO) is found

in many areas such as any type of internal combustion engines, heat-

ers, charcoal grills, cooking ranges and any other open flame applianc-

es. There are many possible variables for the accumulation of carbon

monoxide. Wind direction, boat speed, vessel proximity to other vessels or

structures are just a few of the possible variables that would permit

exposure to carbon monoxide gases. It is important that regular inspec-

tions of the exhaust system are conducted and maintenance is properly

performed by a qualified technician. Adequate air circulation in all

areas of your boat are necessary in order to prevent build-up of carbon

monoxide. Please contact your boat manufacturer if you have questions

regarding these hazards.

For more information regarding safe boating practices, and/or carbon

monoxide poisoning on recreational boats, contact the following:

National Marine Manufacturers Association (NMMA)

200 East Randolph Drive, Suite 5100, Chicago, IL 60601

312-946-6200 • www.nmma.org

United States Coast Guard

Office of Boating Safety Chicago, IL - CG Headquarters G-OPB-3

2100 Second Street, SW, Washington, DC 20593

202-267-0984 • www.uscgboating.org

American Boat & Yacht Council, Inc. (ABYC)

3069 Solomons Island Road, Edgewater, MD 21037-1416

410-956-1050 • www.abyc.com

covers engine related defective material and/or workmanship

only, and not replacement or refund of the equipment to which

the engine may be mounted.

This Special Applications Warranty shall NOT apply to nor shall it

extend to repairs required because of the following:

1. Damages caused by failures or inadequacies in the cooling

system;

1. Introduction

2. Safe Boating

DANGER

WARNING

CAUTION

Carbon Monoxide Exposure

Carbon Monoxide is a odorless, colorless and tasteless gas that cannot be

smelled, seen or tasted.

Sustained exposure to carbon monoxide gas may lead to brain damage,

unconsciousness or death.

7www.MarinePowerUSA.com

3. Engine Identication

Every Marine Power Engine is equipped with an Engine Identifi-

cation Tag, also known as a Serial Number Tag. This tag contains

information (model number and serial number) that will be

required before any warranty work (if necessary) can be done.

Airpac:

Engines configured for airboat applications. These engines use

closed cooling systems with automotive style radiators. Their

exhaust manifolds are dry and usually supplied by the boat

builder.

Enpac:

Engines configured for stern drive (I/O) applications. Cooling

water supply differs depending on the stern drive model mated

to. See Section 12: Installation Instructions.

Jetpac:

Engines configured for inboard jet drive applications. Cooling

water normally supplied by jet drive. Routing of inlet out out-

let cooling water lines will affect winterization. See Section 9:

Winterization procedures.

Towpac:

Engines configured for watersport tow boat applications. Engines

may be configured for conventional inboard or v-drive applica-

tion. In many of these applications throttle and shift is highly

integrated with the boat instrumentation

Sportpac:

Engines configured for traditional inboard vessels. Many of these

applications are twin installations.

8www.MarinePowerUSA.com

3. Engine Identication

Engine Type

Repower

Original Equipment

Unique Feature

Displacement

Bore & Stroke

Compression Ratio

Cylinder Block

Cylinder Head

Recommended Fuel

Max RPM @ Wot

Idle RPM

HP Fuel Pressure

LP Fuel Pressure

Oil Pressure @ 2000 RPM

Min Oil Pressure @ Idle

Operating Temp RW Cooled

Operating Temp FW Cooled

Sparkplug Type

Sparkplug Gap

Timing @ Idle

Timing @ 4000 RPM

Firing Order

Alternator Rating

Crankcase Oil

Oil Capacity

Closed Cooling Fluid

Closed Cooling Capacity

5.3 GEN V DI

Direct Injection

5.3L/327 CID

96 x 92 mm

11 : 1

Aluminum

87 Octane

5600

ECM Controlled

60 PSI

4-7 PSI

30-60 PSI

10 PSI

N/A

175° F

12622441

.040”

ECM Controlled

1-8-7-2-6-5-4-3

150 amps

Dexos 15W50 GEN 2

8 Qts.

Antifreeze/Water

10 Qts.

6.2 LT4

DI Supercharged

6.2L/374 CID

103.25 x 92 mm

10 : 1

Aluminum

93 Octane

5600

ECM Controlled

72 PSI

4-7 PSI

30-60 PSI

10 PSI

N/A

170°-190° F

12642722

.040”

ECM Controlled

1-8-7-2-6-5-4-3

250 amps

Dexos 15W50 GEN 2

8 Qts.

Antifreeze/Water

10 Qts.

6.2 GEN V DI

Direct Injection

6.2L/374 CID

103.25 x 92 mm

11 : 1

Aluminum

87 Octane

5600

ECM Controlled

60 PSI

4-7 PSI

30-60 PSI

10 PSI

N/A

170°-190° F

12622441

.040”

ECM Controlled

1-8-7-2-6-5-4-3

150 amps

Dexos 15W50 GEN 2

8 Qts.

Antifreeze/Water

10 Qts.

Ce manuel convient aux modèles suivants

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