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· 844-GO-ILMOR (464-5667)  www.ilmor.com

OWNER’S MANUAL

June 2019

ILMOR Engines

Summary of Contents for 5.3L GDI

Page 1: ...I 844 GO ILMOR 464 5667 www ilmor com OWNER S MANUAL June 2019 ILMOR Engines ...

Page 2: ......

Page 3: ...Warranty Statement Due to technological advancements and continuous improvement of our products and products of our component suppliers Ilmor reserves the right to change specifications without notification Photographs and illustrations used in this Owner s Manual are intended only as representative reference views and may not depict actual model component parts Ilmor Marine LLC Ilmor is pleased t...

Page 4: ...TIONS AND DESCRIPTIONS 12 EXHAUST SYSTEM 12 FUEL SYSTEM 12 COOLING SYSTEM 12 Open Cooling System 13 Closed Cooling System 13 Quick Drain Procedure GDI S Models 14 Flushing Procedure 15 ELECTRICAL SYSTEM 15 Power Distribution Module PDM Custom Inboard Series 16 Electronic Power Distribution Module ePDM 16 Boat Engine Interface Wiring 16 ENGINE SENSORS 17 ALARMS 17 Water Temperature 17 Oil Pressure ...

Page 5: ...USE 21 Check Engine Oil Cold 21 Check Sea Strainer 22 Check Coolant Level 23 Check Power Steering Fluid S Models 24 Check Serpentine Belt 24 Check Battery Connections and Hold Downs 25 Check Battery for Full Charge 25 Inspect Engine and Engine Cables 26 Inspect Fuel and Exhaust Systems for Leaks 27 AFTER EACH USE 27 NEW ENGINE BREAK IN 27 First Hours of Operation First 25 Hours 29 After First Hour...

Page 6: ...ENANCE SCHEDULE 33 CHECK ENGINE OIL WARM 35 CHECK TRANSMISSION FLUID OIL LEVEL 35 SERPENTINE BELT 35 Inspect Serpentine Belt 35 Replace Serpentine Belt 36 CLEAN ENGINE COMPARTMENT AND PREVENT CORROSION 37 INSPECT AND CLEAN THE BATTERY CONNECTIONS AND HOLD DOWNS 37 STORAGE AND WINTERIZATION 38 Fuel System Treatment 39 Battery Winterization 39 Recommissioning After Storage Winterization 39 EMISSIONS...

Page 7: ...l 41 OBD M 41 CALIFORNIA AND U S EPA EMISSION CONTROL WARRANTY STATEMENT 42 Warranty Rights and Obligations 42 Warranty Terms 42 Owner Warranty Responsibilities 43 General Emissions Warranty Coverage 43 Mechanical Emission Related Components Warranty 44 Electronic Emission Related Control Parts Warranty 44 Direct Emission Related Control Parts Warranty 45 TROUBLESHOOTING 46 SPECIFICATIONS 48 ...

Page 8: ... activate and keep the limited warranty statement in effect throughout the applicable warranty period Continuing appropriate maintenance and care can ensure long term enjoyment of the engine DO NOT OPERATE ENGINE WITHOUT FIRST READING THE ENTIRE OWNER S MANUALAND ALL SUPPORTING DOCUMENTATION AS WELLAS THE BOAT OWNER S MANUAL For locating the nearest authorized Ilmor service center please visit htt...

Page 9: ...ner operator responsibility to ensure full compliance with all applicable safety codes and requirements All requirements of the Federal Occupational Safety and Health OSH Act must be met when Ilmor products are operated in areas that are under the jurisdiction of the United States of America Ilmor products operated in other countries must be installed operated and serviced in compliance with any a...

Page 10: ...bon monoxide can cause serious injury or death in a short period of time DANGERS WARNINGS CAUTIONS AND NOTICES Safety alert symbol appears with most safety statements It means attention become alert personnel safety is involved Please read and abide by the message that follows the safety alert symbol WARNING Indicates a potentially hazardous situation which if not avoided could result in death or ...

Page 11: ...enuine Ilmor replacement parts intended for the engine The electrical and ignition components have been designed to comply with U S Coast Guard regulations intended to minimize the possibility of fire and or explosion The use of non approved replacement parts from aftermarket or other sources will void the warranty and could result in fire and or explosion which could result in serious injury or d...

Page 12: ...and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust service your vessel in a well ventilated area and wear gloves or wash your hands frequently when servicing this vessel For more information go to www P65warnings ca gov marine WARNING Battery posts terminals and related accessories may contain lead and lead compounds These chemicals are known to the State of ...

Page 13: ...ed service intervals NOTICE Engines operating in brackish or salt water should be flushed with fresh water after every use Void water on open cooled side NOTICE Lack of water to the engine cooling system could cause the raw water impeller to fail and lead to severe engine problems Any leaks or restrictions to the inlet or outlet side of the engine cooling system should be repaired immediately befo...

Page 14: ... draws water into the engine where it is distributed to the engine s cooling system Exhaust manifolds are water cooled to regulate exhaust temperatures If an odor of burning rubber or other materials exists shut down the engine immediately and move to a safe location Prepare an on board fire extinguisher and check for water exhaust gas leaks or restrictions of the engine exhaust and cooling system...

Page 15: ...Ilmor engines use two main types of cooling systems Available cooling system types are determined by the model of engine selected 1 Open Cooling System In an open cooling system the entering water flows directly through the cooling passages of the engine exhaust manifolds and discharges out the tailpipes 2 Closed Cooling System Ocean Performance Series In a closed cooling system the entering water...

Page 16: ...edure after each use of the engine operation It prevents build up marine growth corrosion and blockage in the raw water system The steps below describe how to use this integrated feature 1 Verify engine is OFF 2 Remove emergency stop lanyard from safety switch Leave throttle shift control lever in neutral 3 Close the seacock if equipped 4 Remove the flush port cap which will act as a siphon break ...

Page 17: ...ment or personal injury WARNING Always disconnect the negative battery cable first before disconnecting the positive battery cable After the negative battery cable is disconnected the positive battery cable can be disconnected This minimizes the possibility of electrical contact which may result in serious injury or death 1 Pressurized winterizing kits will consist of a container a corresponding f...

Page 18: ...cover from the ePDM as this will void your warranty Boat Engine Interface Wiring Electronic Power Distribution Module ePDM DO NOT remove the cover from the ePDM Positive battery post is connected to the large post on the starter motor with marine grade single ought 1 0 starter wire and appropriate terminal connection After connection is made all other positive engine circuits will be connected to ...

Page 19: ...are equipped with a variety of audible and visual alarms that alert operators to potential performance issues No alarm whether it sounds an alert or provides information on the gauges should ever be ignored The powertrain sensors are often the earliest indication of problems and if ignored may result in serious damage to the equipment that is not covered under warranty The alarm activation will di...

Page 20: ... occurs shut engine off immediately if safe Check oil level Running the boat at this point represents an unknown risk It would be best to have the boat serviced before resuming normal operation Displays the status of battery charge and charging system With engine running voltmeter should read between 13 and 14 7 volts Oil Pressure Voltmeter Oil pressure gauge Voltmeter ...

Page 21: ...fueling If gasoline is spilled immediately wipe up all traces with dry rags and dispose of rags properly on shore Gasoline and gasoline vapors may cause fire or an explosion when starting the engine which will result in serious injury or death WARNING Replace fuel system parts with only Ilmor authorized parts All fuel system lines and connections must meet the requirements of U S Coast Guard USCG ...

Page 22: ...se Fuel Requirements Oxygenated Gasoline or Gasoline Con taining Alcohol ignition timing Higher octane fuel causes less knock for the ignition system to process and adjust timing Poor quality or old fuels can cause problems such as loss of performance rough idling hard starting and hesitation If the engine experiences any of these symptoms first try another brand of gasoline and then replace the o...

Page 23: ...rom an authorized Ilmor service center to properly prepare the powertrain for periods of inactivity exceeding 30 days Damage due to improper storage or winterization preparations is not covered under warranty Check engine oil level prior to starting even though a more accurate level reading occurs on an engine running at operational temperature Perform oil level check with the boat level at rest a...

Page 24: ...ng severe engine problems NOTICE Checking sea strainer is a critical function of routine maintenance Even waterways that appear clean may have debris such as pine needles or moss that can enter the cooling system and create a blockage Failure to check sea strainer can result in serious overheating of the engine Damage to the engine and or transmission caused by overheating is not covered by warran...

Page 25: ...olant at the proper level will cause potentially serious engine damage The warranty does not cover engine damage due to overheating or any other cause associated with improper coolant levels MAX FILL line while the engine temperature is equal to ambient air temperature COLD GDI S series closed cooling reservoir cap and tank MPI S series only closed cooling reservoir cap and tank 4 If coolant level...

Page 26: ...tegrated dipstick level gauge MAX Mark MIN Mark 1 2 1 2 Check Serpentine Belt 1 Verify engine ignition and battery switches are in the OFF position 2 Open engine compartment cover and visually inspect serpentine belt for material defects or indications of wear to include missing material cracking layer separation splits cuts etc 3 Verify pulleys are secure aligned dry smooth and undamaged 4 Close ...

Page 27: ...ontains sulfuric acid which is poisonous corrosive and caustic If exposed to battery electrolyte flush the area with large amounts of clean water and immediately seek medical attention WARNING Keep sparks flames and smoking materials away from battery charging area When charging batteries generate small amounts of dangerous highly explosive hydrogen gas Failure to follow OEM instructions for charg...

Page 28: ...ift control lever in neutral 2 Open engine compartment and inspect engine engine components and mounts for loose and missing hardware If found visit an authorized Ilmor service center for maintenance Check cable connections CHECK FOR KINKS WEAR AND INTERFERENCE OF THROTTLE AND SHIFT CABLES Follow each cable back under the floorboards and feel for any kinks or wear on the outer jacket Immediately r...

Page 29: ... starting switch is disconnected 2 Open engine compartment and check fuel and exhaust systems for leaks gaps or cracks 3 Start engine and check for fuel and exhaust leaks 4 If any leaks gaps or cracks are discovered contact authorized Ilmor service center immediately for repair DANGER If at any time during operation there is an unexplained odor or if anyone onboard shows signs of unexplained drows...

Page 30: ...owertrain may have been lake tested by the boat manufacturer the break in period starts when the retail consumer takes possession of the boat and follows the instructions provided in this Owner s Manual WARNING Never operate engine without adequate and uninterrupted water flowing through the cooling system This requires the boat to be in an operational sized body of water or connected to the sucti...

Page 31: ...r fire resulting in serious injury or death After First Hours Of Operation After First 25 Hours 1 After engine break in and oil change have been completed engine may be operated more continuously at speed but never beyond the maximum allocated speed It is always advisable to give the engine an occasional cool down period 2 Throughout the life of the engine allow for a warm up period before operati...

Page 32: ...once engine begins to crank Automatic start feature will crank engine until it is running Key Switch Start START ENGINE 1 After performing all the checks and inspections outlined in this Owner s Manual lift the engine compartment cover DANGER Open engine compartment and check for fumes leaks or presence of fluids in bilge before starting engine Failure to do so could result in fire or explosion an...

Page 33: ...c engine model operating temperatures After engine has warmed to operating temperature check engine oil level prior to moving See Check Engine Oil Level section in the Maintenance chapter of this manual SHIFT GEARS STOP THE BOAT Ensure engine is at normal operating temperature prior to placing boat in gear When shifting gears always move the throttle shift control lever smoothly and quickly into g...

Page 34: ...ccount effects of area conditions such as tides currents winds weather and or passing wakes of other nearby vessels These variables will affect the overall time and distance of the stopping procedure These recommendations are for IDEAL stopping conditions only Emergency stopping situations call for actions that are at the sole discretion of the vessel operator to deem necessary for safety Ilmor is...

Page 35: ...rding to circumstances and good judgment If there is any doubt please seek assistance from an authorized Ilmor service center In addition to the routine services addressed earlier there are a number of other maintenance procedures that require periodic attention The following table indicates the maintenance schedule Scheduled Maintenance Chart Engine Service Item Before Each Use Annually Season St...

Page 36: ...er I1 I1 I1 R If the engine is subject to heavy usage it is required to perform these maintenance items at half time of the interval shown Heavy usage is defined as operators using their vessel under the following conditions loaded with additional ballast and or weight to achieve total maximum capacity over the OEM specification commercial or training purposes as defined in the Ilmor warranty at w...

Page 37: ... tensioner 1 Ensure engine is OFF and the engine safety starting switch is disconnected Leave the throttle shift control lever in neutral Open engine compartment and locate the serpentine belt 2 Check serpentine belt tension at the top midway between the circulating pump pulley and the alternator pulley The belt should be tight enough so that it will deflect no more than 1 4 to 1 2 in 6 to 13 mm w...

Page 38: ...n 3 Remove serpentine belt by unwrapping it from each of the pulleys 4 Inspect serpentine belt for wear 5 After determining the serpentine belt replacement needs reinstall and route the serpentine belt according to the belt routing label affixed to the engine 6 Ease the tensioner back into place and ensure that the belt is properly routed around all of the pulleys 7 Listen for irregular audible no...

Page 39: ...ecked severe damage may occur over time A boat properly prepared for operation in salt water will have sacrificial anodes mounted on the transom and possibly elsewhere underwater These anodes are intended to reduce the effects of galvanic corrosion to critical metal areas of the boat The sacrificial anodes should be checked regularly and when significant erosion is shown the anodes should be repla...

Page 40: ...a certain level of cold cranking amps at 0 F 18 C Check the boat manufacturer s owner s manual to determine what this specification is Before disconnecting the battery ensure ignition key and all accessories are in the OFF position Take care to reattach battery cables correctly to avoid reversed polarity which is addressed in the electric system section in the FUNCTIONS DESCRIPTION chapter of this...

Page 41: ...re Ilmor affixes each engine with a tamper resistant Emission Control Information ECI label This label affirms the required emissions compliance statement along with the engine family the Family Emission Limit FEL and engine displacement if applicable The ECI label contains the date of manufacture For inboard sterndrive engines the label is located at the rear of the engine on an angled face of th...

Page 42: ...tered in California must have a Star Label affixed to the port side of the hull either forward or aft of the vessel registration as shown in the following illustration A conventional power 373 kW 500 bhp or less Ilmor GDI engine has a Five Star Extremely Clean Emission rating This indicates that the engine has 50 lower emissions than Four Star Super Ultra Low Emission engines A Star Label is place...

Page 43: ... appear on the dash when emission system problems occur on the boat If the MIL is set due to an emissions related fault a Diagnostic Trouble Code DTC will register The MIL functions to notify the operator that a problem has occurred so that the owner operator can arrange for service as soon as possible DTCs are stored in the Engine Control Unit memory and can be retrieved with a diagnostic scan to...

Page 44: ...iagnosis parts and labor Select electronic emission related control parts from model year 2020 and later sterndrive inboard engines are warranted for 3 years or 480 hours whichever first occurs Select mechanical emission related components are warranted for 3 years or 480 hours whichever first occurs This includes engines with maximum power less than or equal to 373 kW 500 bhp Engines with maximum...

Page 45: ...ge Ilmor must warrant that the engine is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code and by the U S EPA pursuant to 40 CFR 1045 2 Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all materia...

Page 46: ...ilation PCV pipe Fresh air pipe PCV hose connector Valve cover grommet Oil filler cap Exhaust Exhaust manifold tailpipe not includ ed Exhaust valve s Miscellaneous Items Clamps Fittings Sealing gaskets or devices Mounting hardware Covered up to but not including the first required replacement only See the Maintenance Schedule in the Owner s Manual 5 7L 5000MPI only Electronic Emission Related Cont...

Page 47: ...4 5667 www ilmor com Direct Emission Related Control Parts Warranty Systems Covered by this Warranty Parts Description Catalytic Converter Catalytic converter s Oxygen sensor Evaporative System Low permeation non metal fuel hose s ...

Page 48: ...e safety switch tether Shift to neutral Reset the circuit breaker Clean the battery terminals Charge or replace the battery Clean and tighten the battery wiring connectors Replace the starter solenoid See authorized Ilmor service center Replace the neutral safety switch See authorized Ilmor service center Replace the starter motor See authorized Ilmor service center Engine turns over but will not ...

Page 49: ...on and or remove any excess weight within the vessel Have dealer replace the fuel filter Poor fuel mileage Plugged spark arrestor Inefficient driving habits Plugged PCV valve Weak or faulty ignition system components Incorrect boat profile Clean the spark arrestor Plane the boat quickly then slow down to desired speed Have dealer replace the PCV valve See authorized Ilmor service center Correct th...

Page 50: ...cement L 5 33 5 96 6 16 7 44 Compression Ratio 11 0 1 9 6 1 11 5 1 10 7 1 Firing Order 1 8 7 2 6 5 4 3 Gasoline Fuel Recommendations Unleaded 90 93 R M 2 Octane up to 10 Ethanol Unleaded 87 93 R M 2 Octane up to 10 Ethanol Unleaded 90 93 R M 2 Octane up to 10 Ethanol Unleaded 87 93 R M 2 Octane up to 10 Ethanol Max Engine RPM 5 600 5 200 5 600 5 800 Engine Oil Type Pennzoil Platinum Full Synthetic...

Page 51: ... R M 2 Octane up to 10 Ethanol Heavy usage is defined as operators using their vessel under the following conditions loaded with additional ballast and or weight to achieve total maximum capacity over the OEM specification commercial or training purposes as defined in the Ilmor warranty at water temperatures below 55 F 13 C at elevations greater than 6000 feet 1830 meter above sea level and or wid...

Page 52: ...r 50 50 Mix Coolant Capacity if equipped 5 gal 18 L to 6 gal 22 L Normal Operating Temperature Range 160 F 71 C 190 F 88 C These engine specifications are the declared values for United States Environmental Protection Agency EPA If the engine is subject to heavy usage the minimum gasoline fuel requirement is Unleaded 90 R M 2 Octane up to 10 Ethanol Heavy usage is defined as operators using their ...

Page 53: ...L Normal Operating Temperature Range 130 F 54 C 190 F 88 C These engine specifications are the declared values for United States Environmental Protection Agency EPA If the engine is subject to heavy usage the minimum gasoline fuel requirement is Unleaded 90 R M 2 Octane up to 10 Ethanol Heavy usage is defined as operators using their vessel under the following conditions loaded with additional bal...

Page 54: ...ngine Oil Filter Engine Timing 5000MPI ONLY Engine Fuel Filter s Heat Exchanger s One Drive Fluid Filters Magnet Power Steering Fluid PRV Pressure Relief Valve Raw Impeller Sacrificial Anodes Engine Sacrificial Anodes One Drive Serpentine Belt Shaft Alignment Spark Arrestor Spark Plug Wires Spark Plugs Transmission Fluid ...

Page 55: ...NAUTICAL NOTES ...

Page 56: ...NAUTICAL NOTES ...

Page 57: ...NAUTICAL NOTES ...

Page 58: ... 844 GO ILMOR 464 5667 www ilmor com 06 01 2019 Version 1 0 ...

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