Indmar 5.7L MPI Operator'S Manual Download Page 1

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Operator ’s Manual

Part No. OME0502-15

Printed in U.S.A.

The first production inboard equipped with catalytic converters.

Ken Cook Co.

5400 Old Millington Road Millington, TN 38053

w w w. i n d m a r. c o m

OME0502-15 Cover.qxp_OM0502-05 Cover.qxd 4/28/14 10:27 AM Page 1

Summary of Contents for 5.7L MPI

Page 1: ...Operator s Manual...

Page 2: ...e engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING OME0502 15 Cover qxp_OM0502 05 Cover qxd 4 28 14...

Page 3: ...the presence of a hazard which WILL or CAN cause MINOR or MODERATE personal injury or property damage NOTICE Indicates installation operation or maintenance infor mation which is important but not ha...

Page 4: ...milies 5 7L Electronic Fuel Injected 6 0L Electronic Fuel Injected L96 6 2L Electronic Fuel Injected LS3 LSA ENGINES COVERED The information in this manual applies to the following Indmar branded GM b...

Page 5: ...ts line of marine inboard engines equipped with catalytic converters Indmar s ETX CAT system reduces exhaust emis sions including carbon monoxide CO to provide a cleaner and safer boating experience f...

Page 6: ...he world s finest most advanced and most dependable gasoline inboard marine engines at the best possible price while respecting the needs of our employees customers vendors and the precious environmen...

Page 7: ...Engine Does Not Start 3 3 How to Clear the Engine 3 3 Engine Restart 3 4 Chapter 4 Normal Operation 4 1 Sensible Operation 4 1 Daily Routine 4 1 Operating the Controls 4 3 Unusual Vibration 4 4 Fuel S...

Page 8: ...8 Engine Cooling 6 8 Internal Cooling System Care 6 12 Fuel System 6 14 Transmissions 6 14 Electrical System 6 19 Wiring 6 20 Chapter 7 Storage and Winter Lay up 7 1 General Preparation 7 2 Reactivati...

Page 9: ...er please call 901 353 9930 or visit our website at www indmar com To ensure that the proper information is available note the six digit engine serial number Your dealer should have written the engine...

Page 10: ...e completed your warranty registration to comply with federal regulations This registration enables us to contact you if it should become necessary to change or improve your product The engine serial...

Page 11: ...ndmar The new boat owner will be notified within 10 days of Indmar s receipt of the transfer paperwork whether the transfer has been accepted or not If the transfer has been accepted the warranty expi...

Page 12: ...special environ mental label required by the California Air Resources Board CARB The label has 1 2 3 or 4 stars A hang tag provided with your inboard engine describes the meaning of the star system O...

Page 13: ...rom meeting these requirements The minimum emission related warranty period is 3 years 480 hours whichever comes first The emission related warranty covers all components whose failure would increase...

Page 14: ...rranted by Indmar for the entire warranty period of the engine unless the part is scheduled for replacement as required maintenance in the Operator s Manual Emission warranty parts that are scheduled...

Page 15: ...nsfer of the remaining engine components Emission Maintenance Requirements The following component maintenance is required to maintain the Emission Control System of your engine See Chapter 6 Maintena...

Page 16: ...871003 5W30 Mobil 1 LS3 Models LSA Models N A 751202 Emission Component Part Numbers Following are the Indmar Part numbers for the Emission Maintenance Components Emission Maintenance Procedures Engi...

Page 17: ...he time listed below provided there has been no abuse neglect or improper maintenance of your inboard engine Your emission control system may include parts such as the carburetor or fuel injection sys...

Page 18: ...ailures we see are due to unstable or old fuel and lack of proper lubrication Failures that are attributed to old unstable fuel or lack of lubrication are not warrantable If your engine is operated in...

Page 19: ...t hull and or garboard drain plug Make sure they are installed and secure Check the boat owner s manual for additional pre operation checks 2 Make sure all engine drain plugs are installed Refer to Ch...

Page 20: ...k transmission oil level for correct level Refer to Chapter 6 Maintenance 6 If your engine is equipped with fresh water cooling check the expansion tank for the correct level Refer to Chapter 6 Mainte...

Page 21: ...EFI engine for the first time This allows the electric fuel pump to fill the fuel injec tion lines with gasoline Each time you advance the ignition switch to the ON position the fuel pump cycles for...

Page 22: ...n sense for the first 10 hours Break in Tips Always let engine warm up to normal operating tem perature before accelerating Avoid fast accelerations and don t carry or pull a heavy load during this pe...

Page 23: ...best equipped to check the engine immediately after break in After the break in procedure is over your boat may be operated at any speed Be sure to check the wide open throttle operating range refer...

Page 24: ...1 6 Indmar Marine Engines OME0502 15 Body qxp_OM0502 05 Body qxd 5 20 14 12 45 PM Page 1 6...

Page 25: ...ur boat at least once a day for gasoline fumes oil leaks and areas where wiring may be worn or damaged Explosive gasoline and battery fumes may accumulate in your engine compartment Failure to properl...

Page 26: ...e DO s and DON Ts still be followed Please follow these DOs and DON Ts to ensure a safe boating experience every time DON T swim or sit near the swim platform when any engine is running DON T hold on...

Page 27: ...e engine or through the heat exchanger on closed cooled engines Freezing tempera tures will severely damage the engine block cooling system components and exhaust system components Contact your dealer...

Page 28: ...3 Engine Oil Filter 7 Check transmission fluid level Check V Drive fluid level if equipped 8 If your engine is equipped with a fresh water cooling system check coolant level in the expansion tank 9 Ch...

Page 29: ...ar and abrasion 14 Verify throttle shift control is functional and properly adjusted 15 Verify steering controls are functional and properly adjusted 16 Verify battery connections are clean and secure...

Page 30: ...2 6 Indmar Marine Engines OME0502 15 Body qxp_OM0502 05 Body qxd 5 20 14 12 45 PM Page 2 6...

Page 31: ...ing and after the re fueling operation Failure to do so may result in fire or explosion and may cause death or serious injury Never remove or modify any components of the engine s fuel system Tamperin...

Page 32: ...detent button on the shift control box pulled out 4 When the engine starts to crank you can release the key and let Smart Start take over When the engine starts it will gradually slow from a fast idl...

Page 33: ...wn for two minutes disengage the shift interlock and advance the throttle lever about 1 4 of its total travel Turn the key to START again and see if the engine starts If your engine does not start aft...

Page 34: ...e sure that your throttle lever is in NEUTRAL 3 Turn key OFF Try to start engine again If it does not start disengage the shift interlock and advance throttle to about 1 4 while holding key in the STA...

Page 35: ...han the boat was designed to handle Damage to the engine that can be attributed to excessive RPM and or loading may not be covered by the engine s limited warranty DAILY ROUTINE 1 Open the engine cove...

Page 36: ...ngine is started allow it to reach operating temperatures of at least 120 140 F 49 60 C before accelerating to speeds above 3000 RPM Figure 4 1 Typical Temperature Gauge 4 Monitor your gauges and warn...

Page 37: ...nly in the neutral position If during the starting process your engine will not turn over make sure that the shift throttle control is in the NEUTRAL position and try again Most boats have an engine s...

Page 38: ...L SYSTEM The Indmar fuel system uses high quality marine grade components These components will tolerate small amounts of water without sustaining damage Your engine will misfire and run poorly howeve...

Page 39: ...age electrical components These dam ages are not covered by your warranty SERVICE REQUIRED OR CHECK ENGINE INDICATOR EFI ENGINES ONLY Some boats are equipped with a digital dash which dis plays the wo...

Page 40: ...es for blockage or problems Follow the boat manufacturer s instructions if the sea strainer is blocked CHECK TRANSMISSION LIGHT If the engine is equipped with the Walters V Drive trans mission there m...

Page 41: ...h the water intake Inspect your water pump impeller annually or more often if you operate your boat in shallow water or run it aground Impeller failure will result in an overheated engine Running your...

Page 42: ...erous All engines and fuel burning appliances produce CO as exhaust Direct and prolonged expo sure to CO will cause BRAIN DAMAGE or DEATH Signs of exposure to CO include nausea dizziness and drowsines...

Page 43: ...r propped Install a lower pitched propeller to increase WOT RPMs An engine that is under revving is lugging Lugging places tremendous loads on the pistons crankshaft and bearings and can cause detonat...

Page 44: ...4 10 Indmar Marine Engines OME0502 15 Body qxp_OM0502 05 Body qxd 5 20 14 12 45 PM Page 4 10...

Page 45: ...lves Others can build up deposits in combustion chambers and may lead to intake valve stick ing These lower levels of additives can have negative impacts on engine performance and vehicle responsive n...

Page 46: ...e fuel disposed of USING OXYGENATED FUELS OR FUELS WITH ALCOHOL Ethyl alcohol ethanol or grain alcohol is acceptable as long as it is a blend and the blended fuel contains no more than 10 ethanol Fuel...

Page 47: ...e parts When servicing the electrical ignition and fuel systems it is extremely important that all components are properly installed and tightened If not any electrical or ignition component could per...

Page 48: ...Salt Water Operation por tion of this chapter for details Never operate engine without adequate water supply to the raw water pump Failure to properly cool engine will cause severe engine damage and v...

Page 49: ...k Plugs Replace X Fuel Injectors Inspect Clean X Fuel Filter Replace X Engine Timing Check X X Engine Tune Up X Flame Arrestor Clean Change X Belts Inspect X X X Shaft Alignment Check X X Spark Plug W...

Page 50: ...more of the engine s capacity The harder you work the engine the more consumables gasoline and oil it needs to keep running As long as there are not other detrimental operating characteristics such a...

Page 51: ...e the full mark on the dipstick the engine may be damaged Indmar uses and recommends marine 15W40 in all 5 7L and 6 0L engines and Mobil 1 5W30 in all 6 2L engines These oils meet or exceed the API Se...

Page 52: ...e conditions oil change intervals Changing Oil Change your engine oil after the first 10 20 hours of operation Then change oil every 50 hours 25 in severe conditions or annually whichever comes first...

Page 53: ...up always carefully inspect oil drain plug and oil filter gasket area for leaks 8 Stop the engine and re check oil level Add if neces sary Oil Additives Do not use oil additives Indmar engines do not...

Page 54: ...ur engine is eqipped with a K N high performance element type flame arrestor special procedures are required Special servicing instructions for this flame arrestor can be found on the K N website www...

Page 55: ...lable from your Indmar dealer A typical home water supply cannot supply enough water to operate the engine at high RPM Do not run the engine above 1000 RPM when connected to a hose home supply Monitor...

Page 56: ...heat is registered on the temperature gauge Only after the engine is completely cooled is it safe for you to remove the coolant reservoir cap to check the level Failure to follow procedure may result...

Page 57: ...hard water maintenance will not be covered under the Indmar Limited Warranty The following engines must not be operated in brackish or salt water environments unless equipped with a closed cooling sy...

Page 58: ...rough the cooling system For more convenient flushing ask your dealer about permanently installing a flushing device that allows easy connection of a water hose Fresh Water Cooling Half Systems A fres...

Page 59: ...the complete manifold riser assembly and will not have the riser corrosion issues associated with the two piece manifold riser assemblies Fresh Water Cooling All Systems All fresh water cooling syste...

Page 60: ...is under pressure and must be relieved before servicing Because of the inherent danger of fuel leakage into the bilge do not attempt servicing or maintaining compo nents of the fuel system Your Indmar...

Page 61: ...15 1 Dipstick Figure 6 9 Midships Mount ZF Hurth Marine In Line 1 Dipstick Figure 6 10 Stern Mount ZF Hurth Ski Vee or Indmar Vee Throughshaft Models 1 1 1 OME0502 15 Body qxp_OM0502 05 Body qxd 5 20...

Page 62: ...Dipstick Figure 6 11 Stern Drive Walters V Drive and ZF Hurth In Line 1 Dipstick Figure 6 12 Stern Mount ZF Hurth Ski Vee or Indmar Vee Undershaft Models 1 1 1 1 OME0502 15 Body qxp_OM0502 05 Body qx...

Page 63: ...urth in line transmission for shifting Be aware that the Walters V Drive uses motor oil for lubrication while the ZF Hurth transmission uses Automatic Transmission Fluid The Walters V Drive also has a...

Page 64: ...trailer The transmission dipstick is located on the top of the transmission Dipsticks may be marked ADD and FULL or H and L high and low maintain fluid level between the two marks 1 Remove the dipstic...

Page 65: ...Figure 6 15 Fuse Block EFI fuses are located in the holder Figure 6 15 attached by the ECM To remove or inspect a fuse remove molded plastic cap from fuse holder Inspect fuse and replace if it is def...

Page 66: ...ypes of failures are not covered by Indmar s Limited Warranty 2 POOR CONNECTIONS When there is a defective connection between the battery and alternator charg ing current will be forced to find an alt...

Page 67: ...rged battery to a fully charged con dition The excessive current draw can overheat the diodes and cause them to fail If you have a dead bat tery use a battery charger instead If you experience a batte...

Page 68: ...6 22 Indmar Marine Engines OME0502 15 Body qxp_OM0502 05 Body qxd 5 20 14 12 45 PM Page 6 22...

Page 69: ...e is not covered under terms of Indmar s limited warranty Because of the complexity of preparing your engine for winter storage and the danger of catastrophic engine damage from freezing water in the...

Page 70: ...d Engines Only Fuel System Treatment 1 If the boat is to be placed in storage with fuel in the tank s that does not contain alcohol fill the fuel tank s with fresh fuel and a sufficient amount of Mari...

Page 71: ...Scheduled Maintenance Chart 5 Loosen all accessory drive belts and check condition Replace belt s if cracked or damaged 6 Drain seawater section of the cooling system NOTICE Placing all drain plugs im...

Page 72: ...3 Remove the raw water pump impeller from the pump housing Replace annually 4 Remove the hose from the lower rear end of the transmission cooler Inspect the cooler for any debris such as weeds plastic...

Page 73: ...ooling section of the V drive transmission a ZF Ski Vee On these units you can drain the water by removing the two anodes 1 Figure 7 4 or by removing one of the hoses that are attached to the unit If...

Page 74: ...pointed toward the engine to drain the cooler Figure 7 5 ZF Through Shaft Ski Vee Water Drains c Indmar Vee On these models you must remove the plug from the rear of the V drive to drain the cooler F...

Page 75: ...e V drive to drain the cooler Figure 7 7 Indmar Vee Through Shaft Drain Plug e Walter V Drive On these models you can drain the water from the cooler by removing one of the water drain plugs Figure 7...

Page 76: ...and knock sen sor stud must be carefully removed to drain that side of the block NOTICE On the 6 0 and 6 2 Liter engines removing the knock sensor does NOT drain the block Remove the caps from the bra...

Page 77: ...is a sacrificial anode The active material on a new anode is approximately 1 1 2 inches long If the anode is 3 4 19 mm or less it must be replaced with a new P N S865055 anode Figure 7 11 4 Remove th...

Page 78: ...plugs in the back of the exhaust manifold and or reconnect exhaust manifold drain hoses 3 Coat the threads of the block drains with pipe sealant and install in the engine block EFI engines may have kn...

Page 79: ...obtained Figure 7 12 Prop Shaft Flange Alignment NOTICE With the boat in the water or a hose and adapter installed cycle the key switch ON then OFF for five second intervals 2 4 times before cranking...

Page 80: ...lter 6 Install a new raw water pump impeller 7 Check all belts and hoses for cracks and wear Replace as needed 8 Install new spark plugs Check the wires for cracks and damage 9 Charge the battery and...

Page 81: ...e boat loads weight 8 Damaged or dirty hull 9 High altitude adjustment required 10 Adjustment for temperature extremes required Hard Cold Start 1 Weak or discharged battery 2 Choke held open carburete...

Page 82: ...tune up 5 Engine needs to be adjusted for high altitude operations 6 Engine needs to be adjusted for temperature extremes 7 Carburetor out of adjustment carbureted engines only Hard Start Hot 1 Floodi...

Page 83: ...r Dexron Mercon ZF 63IV V Drive and Reduction Gears 15W 40 motor oil Walters V Drive 15W 40 motor oil API Service SL SJ CI 4 CH 4 CG 4 Indmar Vee Shifting Transmission Dexron ATF V Drive Mobil Delvac...

Page 84: ...5 7L Raw Water Cooled Indmar 985009 All 5 7L Fresh Water Cooled Indmar 986034 All 6 0L and 6 2L LS3 Raw Water Cooled Indmar 985009 All 6 0L and 6 2L LS3 Fresh Water Cooled Indmar 986115 All 6 2L LSA I...

Page 85: ...ating Range at WOT 4600 5200 RPM 5200 5600 RPM Oil Pressure at 1000 RPM 6 PSI 41 kPa Minimum Hot Oil Pressure at 2000 RPM 18 PSI 124 kPa Minimum Hot Oil Pressure at 4000 RPM 24 PSI 166 kPa Minimum Hot...

Page 86: ...nsmission 2 12 Quarts 2L Main Gearbox 1 0 Quart 1 06L V Drive Dexron 3 Indmar Vee Transmission 2 3 Quarts 2 12L Main Gearbox Dexron 3 1 25 Quart 1 18L V Drive Mobil Delvac Synthetic 50 ZF 63IV Transmi...

Page 87: ...ited only to the foregoing obligations as stated herein 3 Customer This Limited Product Warranty is extended only to the original retail purchaser of a boat or the original lessor in the case of a lea...

Page 88: ...ler set up improper service or normal wear and tear f Haul out launch and towing charges g Cost and expense incurred that relate to the removal and or replacement of boat partitions seating or materia...

Page 89: ...issued Indmar reserves the right to retrieve run time run condition data from a Product s Electric Control Module prior to granting any warranty coverage on the Product under this Limited Product Warr...

Page 90: ...st be returned to the retailer from whom the Product was purchased or to any other convenient Indmar authorized dealer To obtain the location of an authorized Indmar dealer or service center in your a...

Page 91: ...NECTION WITH THE DEVELOPMENT DELIVERY USE OR PERFORMANCE OF THE PRODUCT IN ANY EVENT THE LIABILITY OF INDMAR FOR ANY REASON AND UPON ANY CAUSE OF ACTION WHAT SOEVER SHALL BE LIMITED TO THE AMOUNT THEN...

Page 92: ...nt parts INTERNATIONAL WARRANTY PROCEDURES Indmar is excited to expand internationally with our boat builder partners and continually stands behind and supports its power packages that are sold outsid...

Page 93: ...___ Hours ____________ By _______________________________ Date ___________ Hours ____________ By _______________________________ Date ___________ Hours ____________ By _______________________________...

Page 94: ...Printed in U S A The first production inboard equipped with catalytic converters Ken Cook Co 5400 Old Millington Road Millington TN 38053 www indmar com OME0502 15 Cover qxp_OM0502 05 Cover qxd 4 28...

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