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10.

Engine Maintenance

Flame Arrestor

Clean the flame arrestor regularly.
1.  Remove fastener from flame arrestor.
2.   Clean with a suitable solvent and blow dry.
3.   Reverse steps to assemble.

G-Force Fuel System

1.   Position catch basin under filter.
2.   Remove cooling cover.
3.   Unscrew canister bowl.
4.   Pull element down from pump.
5.   Push new element (Part #396007) on pump until click is

felt.

6.   Replace O-ring (included with filter).
7.   Re-install canister bowl on unit - snug tight only.
8.   Two 10-second key ups should prime system.

Fuel Flow Schematic

High Pressure Feed Pump

Outlet (60 PSI)

Low Pressure

Feed Pump

Fuel Filter

Negative

Terminal

IN

OUT

Positive

Terminal

Low Pressure Feed Pump is 4-7 PSI at outlet.

Inlet has a small screen inside fitting. This screen

may be flushed by reversing polarity on electrical

connectors and operating pump in reverse. High

pressure Feed Pump must be unplugged during this

procedure.

Not used on LT4

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Содержание 5.3 GEN V DI

Страница 1: ...4 3 L 5 3 L 6 2 L L T 4 M E F I 7 D I R E C T I N J E C T I O N E N G I N E O W N E R S M A N U A L VERSION 4 ...

Страница 2: ...orce 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 ...

Страница 3: ...cident 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 Suc...

Страница 4: ...ease 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 visi...

Страница 5: ...RECT 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 ...

Страница 6: ...nty 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 ...

Страница 7: ...al 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 tota...

Страница 8: ... 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 n...

Страница 9: ...or 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 wate...

Страница 10: ...11 1 Aluminum Aluminum 87 Octane 5600 ECM Controlled 60 PSI 4 7 PSI 30 60 PSI 10 PSI N A 175 F 12622441 040 ECM Controlled 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 V8 X X DI Supercharged 6 2L 374 CID 103 25 x 92 mm 10 1 Aluminum 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 ECM...

Страница 11: ...d monitors the oil pressure and water temperature The following sensors constantly provide information to the ECM Engine Coolant Temperature ECT Sensor Engine Oil Pressure Sensor Manifold Absolute Pressure MAP Sensor Knock Sensor Camshaft Positioning CMP Sensor Crankshaft Positioning CKP Sensor Intake Air Temperature IAT Sensor combined with the MAP sensor on the 5 7 Throttle Position TPS Sensor P...

Страница 12: ...r become intermittent but a trouble code will be logged for future diagnosis In any case the operator must obtain service by an authorized dealer to determine and repair the exact cause of the malfunction The engine ECM is programmed to control the engine alarm system This system is configured to turn on an instrument panel mounted indicator MIL or Check Engine light and optionally an audible buzz...

Страница 13: ...understand his instrumentation and note any abnormal operating conditions Analog Instrumentation Canbus Instrumentation IMPORTANT Engines are designed to use both buzzers and MIL lamps Buzzers are use to alert operators of severe problems such as Low oil pressure high engine temperature or low fuel pressure See Section 11 Engine Diagnostics and Codes for more information ...

Страница 14: ...osure All relays and fuses are located in the Severe Service Vessel Electrical Center SSVEC This enclosure is capable of withstand ing direct water spray Additionally it contains a Goretex vent which allows humid vapors to escape without allowing water in ...

Страница 15: ...13 www MarinePowerUSA com 6 SSVEC Fuse and Relay Enclosure ...

Страница 16: ...14 www MarinePowerUSA com 6 SSVEC Fuse and Relay Enclosure ...

Страница 17: ...15 www MarinePowerUSA com 6 SSVEC Fuse and Relay Enclosure ...

Страница 18: ...nsom of your boat 2 Engine Shutdown Sudden engine shutdown while the boat is moving may force water into the exhaust system 3 Improper Installation Refer to Section 13 Exhaust Piping An exhaust system without flappers and the specified incline increases the likelihood of water entering the engine 4 Improper Hoisting Operators are sometimes tempted to reduce hoisting time for propeller changes by h...

Страница 19: ... changed Starting Engine EFI DO NOT operate engine without water being supplied to raw water pump as pump impeller and engine will be damaged Operate the bilge blower for five 5 minutes If not equipped with a bilge blower open engine hatch and leave open before starting the engine to remove any explosive vapors from the engine compartment Place shift lever in the neutral position If this is the in...

Страница 20: ...ours of engine operation Any time oil level is checked look for milky discoloration if found consult with your dealer After the first ten 10 hours of engine operation but before twenty five 25 hours return the boat to your dealer for its first engine oil and filter change and initial engine inspection DANGER WARNING CAUTION The LT4 Is a Premium 93 Octane REQUIRED engine The engine will operate at ...

Страница 21: ...rain plugs if equipped from exhaust risers Note the routing of your inlet cooling water hose to make sure there are no locations which may trap water If your engine is attached to a v drive transmission pay particular attention to the draining of the v drive cooler Remove end caps on heat exchanger Inspect for debris and trapped water Remove zinc anode and replace if necessary Spray each of your e...

Страница 22: ...ines Test antifreeze water concentration to assure adequate protection for your location These engines are designed to be self draining however it is recommended that the heat exchanger ends be inspected for de bris and trapped water frequently 6 2 Jetpac For best results use a Vacuum Cooling System Filler when refilling or bleeding engine coolant ...

Страница 23: ...t Level in Tank If Equipped with Closed Cooling 3 3 Inspect and Clean Sea Strainer If Equipped 3 3 Inspect Entire Power Package for Leaks Water Fuel Oil Exhaust etc 3 3 Inspect Belts for Tension and Wear 3 3 Inspect Battery Terminals and Fluid Levels 3 3 Check Battery Connection to Engine 3 3 Touch Up Exterior Surface with Marine Power Paint 3 3 Inspect Zinc Anodes in Heat Exchanger for Deteriorat...

Страница 24: ...ghtness 3 3 Check Riser and Manifold Bolts for Tightness 3 3 3 Check for Loose Damaged or Missing Engine Parts 3 Check Wire Harness Plugs for Corrosion and Connections 3 Check Condition of Spark Plugs Replace if Necessary 3 Inspect Hoses for Deterioration 3 Replace Impeller in Seawater Pump 3 Check Propeller and Shaft Alignment 3 Clean and Inspect Flame Arrestor and Crank Case Vent Hose 3 Change T...

Страница 25: ... be replaced If you cannot re use the same bolt do not improvise Performance could be sacrifice without original Marine Power parts or parts recommended by Marine Power A marine environment is a tough one Parts subjected to salt water can rapidly corrode and engine failure could result Warranty on Marine Power Engines could also be affected if other than recommended replacement parts are used Cran...

Страница 26: ...il shows FULL on dipstick Start engine Run for approximately 5 minutes and inspect for leaks Shut off engine and wait 5 minutes for oil to drain back into pan Check level with dipstick Add oil to proper level if needed ALWAYS CONTACT YOUR NEAREST MARINE POWER SERVICING DEALER IF YOU HAVE A PROBLEM WARNING CAUTION DO NOT overfill crankcase with oil Agitation or splashing of oil may cause it to beco...

Страница 27: ...6007 on pump until click is felt 6 Replace O ring included with filter 7 Re install canister bowl on unit snug tight only 8 Two 10 second key ups should prime system Fuel Flow Schematic High Pressure Feed Pump Outlet 60 PSI Low Pressure Feed Pump Fuel Filter Negative Terminal IN OUT Positive Terminal Low Pressure Feed Pump is 4 7 PSI at outlet Inlet has a small screen inside fitting This screen ma...

Страница 28: ...s own individual battery DO NOT run engines with the battery switches in BOTH or ALL positions This will allow the other engine s battery to be used in case of emergency to start the engine with the dead battery DANGER WARNING CAUTION DANGER WARNING CAUTION DANGER WARNING CAUTION Do not recharge a weak battery in a boat Remove and recharge in a ventilated area away from fuel vapors sparks or fames...

Страница 29: ...e surge tank replaces the heat exchanger filler neck and pressure cap and is pressure capable whereas the recovery bottle is not Maintain the appropriate lev el in the surge tank at all times If coolant is consistently low additional inspection for leaks in the cooling system may be required Filler Neck and Pressure Cap DO NOT remove pressure cap when engine is HOT If coolant is low add the proper...

Страница 30: ...s code when it detects problem with can bus circuit 65558 59 X Cam Bus Stbl Cntrl Message ECM sets code when it detects problem with can bus circuit 65557 X Catalyst Efficiency Test ECM detects failed catalyst efficiency test 65675 76 X 75 indicates odd bank 76 even bank Change Oil Now Soon 65555 Coolant Temp Sensor Sensor fails diagnostic test 110 X Coolant Temp Warning Sensor alerts ECM if coola...

Страница 31: ...y blade Electronic Throttle Control 65618 Electronic Throttle Control 65600 Electronic Throttle Control 65601 02 Electronic Throttle Control 65610 Fuel Pressure Sensor Sensor fails diagnostic test 94 X Fuel Pressure Error Sensor alerts ECM if fuel pressure is too high or to low 94 X X Check or replace filters If problem persists then further diagnostics needed Reduces RPM to 2500 Fuel Pump Relay 1...

Страница 32: ... Air Temperature Warning Sensor alerts ECM if inlet air temperature is too high 105 X X On supercharged engines check intercooler system Reduces RPM to 2500 Main Health Coprocessor ECM problem 65581 X Check the memory power the main power and the ground on ECM May need replacement Malfunction Indicator Lamp Driver ECM sets code if driver fails diagnostic test 66003 X Boat may not be equipped with ...

Страница 33: ...2 odd bank 62 post o2 odd bank 63 pre o2 even bank 64 post o2 even bank Powertrain Relay ECM detects abnormal relay contact voltage 66013 14 X Supercharger Inlet Pressure Sensor Supercharger inlet pressure too high or too low 3563 X Only applicable on supercharged engines Shift Interrupt 66026 Slow Mode Lamp 66010 Speed Based Output 66011 Speed Sensor ECM sets code if speed sensor fails diagnostic...

Страница 34: ... 1F which energizes Fuel Feed Pump Relays Fuel Feed Pump Relays provide 12 volts to 1C and 1G which turns on Feed Fuel Pumps for initial prime Listen for pumps running Bussmann 2 way Connector 5 Bussmann Connector 2 Grey 5C Energized with 12 volts with Battery Switch on Power enters Bussmann A Engine Ground B Not used C B from Starter Post A Ignition to Fuel Injectors B B C Ignition from Helm D In...

Страница 35: ...t Contact On ECM pin J1 63 supplies 12 volts to Bussmann 3F which energizes Starter Relay Starter Relay then provides 12 votls to Bussmann 3H which in turn energizes Start Solenoid Engine cranks Bussmann Connector 1 Black Bussmann Connector 3 Blue A Auxiliary Relay B Auxiliary Relay Control C Fuel Feed Pump 2 D Powertrain Relay Contacts J1 73 E J1 44 Fuel Pump 1 Relay Control F J1 50 Fuel Pump2 Re...

Страница 36: ... or Motor Replace Shift Control in Gear Take Out of Gear Faulty Starter Relay Check Relay in SSEC Box Hydro Lock Remove Spark Plug Look for Water in the Cylinder Engine Emergency Stop Switch Activated Clear DTC Code Engine Cranks But Will Not Start Possible Cause Remedy Faulty Fuel Pump Note That Low Pressure and High Pumps Are Operating Insufficient Fuel Supply Check Fuel Supply Shut Off Valve Ch...

Страница 37: ...e Open Throttle at Full Load Restricted Anti Siphon Valve Remove From Fuel Tank and Verify Spring Pressure Low Compression See Dealer Engine performance can be greatly affected by boat hull and prop condition High Speed Miss Possible Cause Remedy Water in Fuel Inspect Clean Replace Clogged Fuel Filter Change Fuel Filter Insufficient Fuel Supply Approximately 60 PSI Fuel Pressure Must Be Adequate a...

Страница 38: ...Approximately 60 PSI Fuel Pressure Must Be Adequate at Wide Open Throttle at Full Load Poor Fuel Economy Possible Cause Remedy Boat Hull Dirty Clean Check Adjust Incorrect Prop Size or Damage Verify with Dealer or Manufacturer Clogged Flame Arrester Check Clean Replace Low Engine Compression See Dealer Engine Running Too Hot or Cold Raw Water Engines Operate at 145 F Closed Cooled Engines Operate ...

Страница 39: ...n Page 15 for Correct Oil Level Erroneous Oil Gauge Readings Contact Dealer to Perform a Mechanical Oil Pressure Check Incorrect Dipstick See Dealer Incorrect Oil Viscosity or Diluted Change to Proper Oil Oil Pump Malfunctioning See Dealer Excessive Bearing Clearance See Dealer Low Oil Pressure Will Set a Trouble Code and Will Reduce Engine RPM Oil Pressure as Low as of 5 lbs at Idle is Acceptable...

Страница 40: ...e Greater at Higher RPM s Engine Overheating Verify if Engine is Actually Overheating Possible Cause Remedy Low Coolant Level Add Coolant Refer to Bleeding Procedure if Coolant was Low or Not Flowing into Tank Clogged Sea Water Intake Clear Intake Ensure That All Hoses After the Intake are Clear Clogged Sea Water Strainer Clean Sea Strainer Loose Hose Connections Check and Tighten Clamps Sea Water...

Страница 41: ...E Water from Engine Immediately Cylinder Head Gasket Leak Contact Dealer REMOVE Water from Engine Immediately Cracked Block or Cylinder Head Contact Dealer REMOVE Water from Engine Immediately Intake Manifold Gasket Contact Dealer REMOVE Water from Engine Immediately Incorrect Engine Rotation Contact Dealer REMOVE Water from Engine Immediately Remove water by removing spark plugs and turning the e...

Страница 42: ...ransferred to the hull through the engine bed The standard engine has support mounts that are intended to be used on engine beds arranged for 22 24 bolt centers Use adequate bolts for each support Make certain there is no interference on the underside of the engine between the oil pan or other components located in that area and the hull Cooling System Closed cooled engines use a combination of fr...

Страница 43: ...day per day Fuel Hoses 15 0 23 2 Fuel Tank 1 5 28 2 Trailerable Boat 0 40 25 6 32 2 Non trailerable Boat 0 16 27 6 30 2 Exhaust Piping IMPORTANT The boat manufacturer or installing dealer or individual is responsible for properly locating the engine and installing the exhaust system Improper installation may allow water to enter the exhaust manifolds and engine cylinders and severely damage the en...

Страница 44: ...te model automobiles but is new to the boating industry This feature enables the operator to start the engine by momentarily engaging the key switch it is not necessary to hold the key switch The ECM maintains the start er engagement until the engine starts Once the engine starts the ECM prevents the starter from engaging even if the operator mistakenly turns the key switch To ensure proper operat...

Страница 45: ... tank Plumbing into the main engine fuel supply will cause damage to the engine and fuel pump system Fuel Pump Location If the Aero Motive fuel pump is relocated from its mounting location on the engine it must be placed as close to the fuel tank as possible The maximum distance from the fuel tank pick up tube should be no more than 30 The fuel pump must also be placed as low to the bottom of the ...

Страница 46: ...ld be large enough to maintain Manifold Air Temperature at WOT Please note there are 2 bleed points on the LT4 intercooler Verify that coolant is flowing through the system before before running the engine at higher rpm s DANGER WARNING CAUTION 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 LT...

Страница 47: ...45 www MarinePowerUSA com 13 Installation Instructions Adapter Harness for Analog Instrumentation Harness M6 21 Pin to 10 Pin 473063 ...

Страница 48: ...46 www MarinePowerUSA com 13 Installation Instructions Adapter Harness for Digital Gauges Harness M6 M7 472908 ...

Страница 49: ...47 www MarinePowerUSA com 13 Installation Instructions Adapter Harness for Digital Faria Panel Harness MEFI 6 7 472922 ...

Страница 50: ...48 www MarinePowerUSA com 13 Installation Instructions Heater Connections 4 3 6 2 DI To Heater From Heater LT4 Engine ...

Страница 51: ...e routed from the throttle control lever at the helm to a potentiometer located in the engine compartment Makecertainthatthiscableoperatesfreelyandis properly adjusted The adjustable potentiometer stop screws must not be used as the stop for the throttle lever cable assembly at the helm 6 Check the transmission shift cable lever adjustment on Inboard V drive and stern drive applications with mecha...

Страница 52: ... stops for the throttle cable Such use will cause a Correlation DTC DTC s will automatically reset with an ignition switch recycle If the set screws are impeding lever operation they must be backed out If a Correlation DTC continues to set the Potentiometer should be replaced as it is permanently damaged if the Out of Range DTC is setting as soon as the ignition is turned on the likely cause is mi...

Страница 53: ...ate ______________________________________ Name As It Appears On the Credit Card _________________________________________________________________________________________________ Signature _______________________________________________________________________________________________________________________ Mail completed form to Warranty Registration Transfer Marine Power 17506 Marine Power Indus...

Страница 54: ...ce Log SERVICING DEALERS Note If You Are Unable to Locate an Independent Servicing Dealer Please Contact a Marine Power Distributor Closest to You for Further Assistance Date Service Maintenance Performed Performed By Operating Hours ...

Страница 55: ...53 www MarinePowerUSA com Service Log Date Service Maintenance Performed Performed By Operating Hours ...

Страница 56: ...lized in any form or by any means electronic or mechanical including photocopying recording or any information storage and retrieval system without permission in writing from MARINE POWER HOLDING LLC Marine Power 17506 Marine Power Industrial Park Ponchatoula LA 70454 USA www MarinePowerUSA com ...

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