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TABLE OF CONTENTS 

 
 

1.

 

GENERAL INFORMATION 

 

Application ………………………………………………………………….. 
Identification ………………………………………………………………... 
Break in procedure ...………………………………………………………... 
Starting procedure …………………………………………………………... 
Winter storage……………………………………………………………….. 
Procedures after winter storage ……………………………………………... 
Periodic maintenance ……………………………………………………….. 
Technical maintenance specifications ………………………………………. 
Warranty …………………………………………………………………….. 
Dealer & Service directory ………………………………………………….. 
Exhaust manifolds …...……………………………………………………… 
Supercharger and intercooler system ……………………………………….. 
Impeller pump ………………………………………………………………. 
Raw water and fuel connections ……………………………………………. 
Oil filter relocator …………..……………………………………………….. 

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2.

 

ENGINE MECHANICAL  

 

Specifications ……………………………………………………………….. 
Diagnostic … ………………………………………………………………... 
Cylinder block and components ……………………………..……………… 
Front cover, oilpan and components ………………………..………………. 
Fuel system components …..………………………………………………... 
Serpentine belt system …..…………………………………………………... 
Valve cover replacement …………...……………………………………….. 
Rocker arm replacement ………...…………………………………………... 
Valve lifter replacement …………………………………………………….. 
Crankshaft Balancer replacement ….. ………………………………………. 
Engine front cover replacement …………………………………………….. 

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Timing chain replacement ………………………………………………….. 
Camshaft replacement .……………………………………………………... 
Crankshaft rear oil seal replacement ..……………………………………… 
Oilfilter adapter replacement .………………………………………………. 
Oil pan replacement ………………………………………………………... 
Oil pump replacement ….…………………………………………………... 
Fuel injection pump removal ……………………………………………….. 
Timing chain wear check …….……………………………………………... 
Engine disassembly and assembly ………………………………………….. 
Engine component description ………………………………...……………. 

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90 
145 

 

Содержание 5L V8

Страница 1: ...CHANICAL Specifications Diagnostic Cylinder block and components Front cover oilpan and components Fuel system components Serpentine belt system Valve cover replacement Rocker arm replacement Valve lifter replacement Crankshaft Balancer replacement Engine front cover replacement 13 18 29 31 33 34 41 45 53 58 61 Timing chain replacement Camshaft replacement Crankshaft rear oil seal replacement Oilf...

Страница 2: ...NSTALLATION Important installation notes Engine Air Intake System Fuel System Exhaust System Cooling System Electrical System Predelivery Predelivery inspection checklist 169 171 180 183 189 196 203 210 218 5 SERVICE INSTRUCTIONS Service information 223 ...

Страница 3: ...pplications The base engine is manufactured at the General Engine Products a division of AM General 92 000 square foot production facility located in Franklin Ohio The Optimizer 6500 base engine is Euro III and QS 9000 certified The engine is marinized and marketed by Marinediesel AB headquarters located in Engelholm Sweden and PPT located in Stillwater Oklahoma ...

Страница 4: ...ld not be run at more than 75 throttle for more than very short time periods Also never have the engine run at excessive loads during the break in apart from this the engine can be used as normal Starting procedure Before starting the engine always check the oil and coolant level Also inspect that no leaks on oil fuel or cooling systems are evident 1 Make sure gear is in neutral and that throttle ...

Страница 5: ...the oil from the engine either by removing the oil plug in the oil pan or by a suction tube down the dipstick tube remember it s always recommended to do this when the engine is at operating temperature Tighten the plug clean the oil dipstick and reinsert it in the tube Then remove the oil filter and replace it with a new unit don t forget to prelubricate the seal ring on the filter and prefill th...

Страница 6: ...ve and clean the battery batteries Also clean the battery cables and connecting poles Store battery in a cold dry environment never below 0C 32F and keep it fully charged Procedures after winter storage x Exhaust System Remove all winter storage seals from exhaust and intake system x Electrical System Reconnect the fully charged battery batteries and tighten lubricate the connectors Check the cond...

Страница 7: ...nt activity or used in any enterprise or venture in which revenue in any amount is generated directly or indirectly The warranty will provide in the First Year Parts and Labor In no case will the warranty cover the cost of removing or installing the engine in the boat pulling the boat out of the water lifts or other associated incidental costs see item VII III To validate the warranty the Warranty...

Страница 8: ...ducts used in combination with company products Other manufacturer s products used in conjunction with Company s Product s are warranted at their own discretion and specifically as indicated by each specific manufacturer XI ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIM...

Страница 9: ...th integrated CuNi intercooler x Crankcase ventilation system Air intake duct and air filter assembly Outside air enters the induction system through a filter located on the intake silencer inlet see picture below This is a bonded cotton wire mesh filter material and should be cleaned and replaced according to service intervals see service book The air filter element mounts to the intake silencer ...

Страница 10: ...8 Air intake adaptor mounts with 6pcs M8 X 25 hexagon socket head bolts Clamps CDR valve Bolted bracket ...

Страница 11: ... The supercharger assembly connects to the intake manifold using a gasket and 7 pcs M8 X 25 hexagon socket head bolts torque to 22 Nm seal with Loctite 270 picture below Intake assembly with integrated CuNi intercooler gasket ...

Страница 12: ...tercooler tank that is covered by a rubber damper to ensure that the intercooler does not get in contact with the casting of the intake manifold Seal the surface between the intercooler tank and the rubber damper with sicaflex or other to make sure it stays in position during assembly Crankcase ventilation system CDR valve Crankcase Depressure Regulator Rubber damper on Intercooler tank ...

Страница 13: ...ump Standard UV1 Commercial high flow Raw water and fuel inlet connections Please see installation section starting page 169 for further information Fuel inlet connection Fuel return connection Raw water connection ...

Страница 14: ...recheck the connections CONNECT FROM ENGINE ADAPTER 1 TO REMOTE OIL FILTER BRACKET IN AND FROM ENGINE ADAPTER 2 TO REMOTE OIL FILTER BRACKET OUT TO CHECK THE CONNECTION MAKE SURE THAT THE OIL HOSES GET WARM WHEN ENGINE IS RUNNING IF THEY STAY COLD RECHECK CONNECTION WARNING BEFORE MOUNTING THE OIL FILTER FILL THE OIL FILTER COMPLETELY WITH OIL THIS TO ENSURE THAT THE ENGINE GETS LUBRICATED DIRECT ...

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Страница 36: ... procedure 1 Install a 3 8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise 2 Remove the drive belt from the drive belt tensioner pulley 3 Slowly release the tension on the drive belt tensioner arm ...

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Страница 152: ...ndition of fluids and observe any leakage from components Engine oil Coolant Air Fuel 2 Inspect the condition and tension of the accessory drive belt 3 Inspect the condition of the outside air intake and air filter element 4 Inspect electrical wiring and connectors Check batteries Generator Starter Fuel shut off solenoid Housing Pressure Cold Advance solenoid Engine speed sensor Oil pressure switc...

Страница 153: ...g all the way Leaking fuel injection lines Check specific gravity of fuel Use fuel quality hydrometer Inspect and clean fuel tank if needed Remove or add oil to correct level drain and refill crankcase if needed Insure boat is properly loaded and operated within RPM limits Review normal operating procedures Disassemble air filter to inspect element with air filter disassembled check outside air in...

Страница 154: ... hydrometer Inspect and clean fuel tank if needed Remove or add oil to correct level Drain and refill crankcase if needed Review correct use of glow plug system Disassemble air filter to inspect element with air filter disassembled check outside air intake Check air inlet duct bolt and clamp tightness check intake manifold bolt stud tightness disassemble and inspect air inlet duct with air inlet d...

Страница 155: ...ank if needed Remove or add oil to correct level Drain and refill crankcase if needed Review normal operation characteristics Review correct use of glow plug system Check fuel system for bleed down Consult your dealer service manager Repair or replace leaking lines Consult with your dealer service manger Consult with your dealer service manger Insure glow plugs are cycling properly Check the follo...

Страница 156: ...eakage or restriction in air inlet duct or intake manifold Restricted exhaust system Incorrect fuel supply to injection pump air in fuel Incorrect fuel return from injection pump Incorrect fuel shut off solenoid operation Check specific gravity of fuel Use fuel quality hydrometer Inspect and clean fuel tank if needed Disassemble air filter to inspect element with air filter disassembled check outs...

Страница 157: ...w plug operation after start up Review normal operating procedures Check throttle controls Check fuel lines at fuel water separator and fuel pump tighten if necessary Check fuel return line on top of injector pump for restrictions or debris Consult your dealer service manager Consult your dealer service manager Consult your dealer service manager Consult your dealer service manager Consult your de...

Страница 158: ...lt your dealer service manager Tighten repair of replace leaking lines Consult your dealer service manager ENGINE SPEED FLUCTUATES PROBLEM CORRECTION FURTHER DIAGNOSIS Incorrect fuel quality water in fuel Incorrect fuel supply to injection pump Internal injection pump fault sticking governor linkage Inspect and clean fuel tank if needed Check fuel line connections at fuel water separator and fuel ...

Страница 159: ...ction lines Faulty fuel injection nozzles Insure boat is properly loaded and operated within RPM limits Review normal operating procedures Disassemble air filter to inspect element with air filter disassembled check outside air intake Consult your dealer service manager Consult your dealer service manager Check air inlet duct bolt and clamp tightness Check intake manifold bolt stud tightness Disas...

Страница 160: ...ug operation Check specific gravity of fuel fuel quality hydrometer Inspect and clean fuel tank if needed Do not idle longer than 10 minutes Review normal operating procedures Consult your dealer service manager Consult your dealer service manager Consult your dealer service manager Check fuel return line on top of injector pump for restrictions or debris Consult your dealer service manager Consul...

Страница 161: ...ter disassembled check outside air intake Consult your dealer service manager Consult your dealer service manager Check air inlet duct bolt and clamp tightness Check intake manifold bolt stud tightness Disassemble and inspect air inlet duct with air inlet duct removed check intake manifold runners Consult your dealer service manager Consult your dealer service manager Check fuel return line on top...

Страница 162: ...ice manager Consult your dealer service manager Consult your dealer service manager Consult your dealer service manager Consult your dealer service manager Tighten repair or replace leaking lines Consult your dealer service manager EXCESSIVE SMOKE DURING ACCELERATION PROBLEM CORRECTION FURTHER DIAGNOSIS Operation with long periods of engine idling Operation while overloaded or at excessive rpm Ope...

Страница 163: ...ith air inlet duct removed check intake manifold runners Consult your dealer service manager Consult your dealer service manager Tighten repair or replace leaking lines Consult your dealer service manager GRAY SMOKE PROBLEM CORRECTION FURTHER DIAGNOSIS Operation with long periods of engine idling Operation during extreme ambient temperature hot cold Outside air intake or air filter restricted Air ...

Страница 164: ... dealer service manager Consult your dealer service manager Consult your dealer service manager Consult your dealer service manager Tighten repair or replace leaking lines Consult your dealer service manager BLUE SMOKE PROBLEM CORRECTION FURTHER DIAGNOSIS Incorrect oil level high low and quality grade viscosity purity Remove or add oil to correct level drain and refill crankcase if needed EXCESSIV...

Страница 165: ...e air intake or air filter restricted Air leakage or restriction in supercharger inlet duct Worn or damaged supercharger Air leakage or restriction in air inlet duct or intake manifold Insure proper fuel is used in engine 2 diesel Do not idle longer than ten 10 minutes Insure boat is loaded properly and operated within RPM limits Review normal operating procedures Check thermostat for low opening ...

Страница 166: ...nsult your dealer service manager Consult your dealer service manager Consult your dealer service manager EXCESSIVE COOLANT CONSUMPTION PROBLEM CORRECTION FURTHER DIAGNOSIS Faulty cylinder combustion area leaking head gasket crushed passages Faulty radiator pressure cap Leaking coolant reservoir hose Leaking cylinder case head coolant passages Consult your dealer service manager Check radiator cap...

Страница 167: ...s of fuel leakage Fuel tank Fuel pick up sending unit Lift pump Lift pump suction pipe hose Fuel filter assembly Fuel filter outlet hose Fuel injection pump x Governor cover x Housing x Head x Drive shaft Fuel injection lines Fuel injection nozzles Fuel return lines x From injection pump hose x At nozzles hoses and caps x From nozzles hoses pipes x From engine to fuel pick up sending unit LUBE OIL...

Страница 168: ...e oveloaded or at excessive rpm Operation during extreme ambient temperature hot cold Incorrect coolant quality grade Incorrect coolant level Faulty radiator pressure cap Faulty circulation pump Leaking coolant tank hose Restricted coolant flow in hoses Restricted coolant flow in cylinder case and cylinder head passages Inaccurate coolant temperature gauge operation Insure boat is properly loaded ...

Страница 169: ...BLEM CORRECTION FURTHER DIAGNOSIS Incorrect oil level high low and quality grade viscosity purity Operation during extreme ambient temperature hot cold Worn or damaged oil pump gears pick up tube screen Faulty oil pump drive or shaft Sticking oil pump pressure regulator valve Oil cooler restricted or bypassed Oil filter bypassed Lube passage leak into crankcase Inaccurate oil pressure gauge operat...

Страница 170: ...ct system for restriction repair or replace damaged parts if needed Inspect exhaust system for collapsed pipes or muffler HIGH INLET RESTRICTION PROBLEM CORRECTION FURTHER DIAGNOSIS Outside air intake or air filter restricted Air leakage or restriction in supercharger inlet duct Worn or damaged supercharger Air leakage or restriction in air inlet duct or intake manifold Disassemble air filter to i...

Страница 171: ...e and that this is of adequate quality so that it doesn t get flat from the fuel feed pump suction If the fuel feed hose line get flat from suction the engine will loose rpm and performance instantly even if it may not run rough x You MUST use double hose clamps on all fuel line fittings to prevent air penetrating into the fuel system x Do NOT use Teflon tape or other to seal fuel or oil fitting u...

Страница 172: ...ne exhaust be run through the transom and NOT run exhaust through the sterndrive as this will lead to excessive backpressure x It is MANDATORY that all MARINEDIESEL engines are propped according to MARINEDIESEL recommendations Over propping of the boat induces excessive loading of the engine which will generate excessive exhaust temperatures and resulting reduction of engine longevity Propping mus...

Страница 173: ...NE Engine Mounting Engine Bed Flexible Engine Mounting Engine Mounts Engine Alignment Checking Stringer Height Suspending the Engine Final Adjustment Mount Height Power Steering Hose Routing Exhaust Hose Routing 172 172 172 173 174 174 175 176 177 178 ...

Страница 174: ...bration and reduces stress on engine casting such as mounts IMPORTANT The finished engine bed or boat stringers must position engine so that a minimum amount of adjustment still exists This is necessary for future adjustments Marindiesel engines are generally equipped with pedestal type flexible front engine mounts Flexible Engine Mounting Generally Marinediesel engines are equipped with pedestal ...

Страница 175: ...tion retain engine mount pedestal to stringer Grade and length of lag screws or bolts must be selected based on stringer material and anticipated loading forces Adjustment nut is turned counterclockwise to raise front of engine or clockwise to lower front of engine Typical Front Mount a Nut And Lock washer b Adjustment Nut c Adjustment Nut d Lag Screws Or Bolts e Tab Washer ...

Страница 176: ...ore installing the engine Tying a string from the port front mount location to the starboard rear engine mount on transom assembly or transmission may check this Another string should be tied from starboard front to port rear The strings should lightly touch where they cross If not corrections should be made to the engine bed ...

Страница 177: ... lifting eyes on the engine are provided to allow attachment of a suitable sling The engine can then be lifted into position in boat using an overhead hoist Before lifting remove the plastic engine cover in order not to damage it A B Engine Lifting brackets a Front b Rear ...

Страница 178: ... so that the engine settles onto the stringers and the mounts are appropriately fastened to stringers Common attachment is using 3 8 in 9 mm lag bolts Both adjustment nuts must be turned equally for proper alignment Alignment must be checked with the alignment tool during the final engine mount height adjustment The locknuts on the mounts should be secured by tightening the adjusting nuts firmly N...

Страница 179: ...arately Proper routing and installation of the hoses is required to avoid problems related to power steering system Observe the following x Hoses must be secured to avoid contact with moving components x Torque both power steering hose fittings to 15Nm after connecting to control valve Power steering oil cooler is standard on all MD engines CAUTION Avoid stress on the hose fittings and avoid kinks...

Страница 180: ...nd entire inside diameter of hose to avoid causing hot spots that could eventually result in burned through exhau hoses Exhaust hoses and or tubes must be correctly connected to exhaust elbows so that they d not restrict the flow of discharge water from elbow Incorrect Correct When installing depending on drivesystem and application the installer may require an installation similar to one of the f...

Страница 181: ...Owners Manual 179 Section 2 Engine Merc Style Through Propeller Exhaust Volvo Y pipe need to be cut to duplicate this ...

Страница 182: ...Owners Manual 180 Section 2 Engine Section 2 AIR INTAKE SYSTEM Engine compartment Engine compartment ventilation General information Combustion air requirements 181 181 181 182 ...

Страница 183: ...mes in the engine compartment Fresh air should enter the engine compartment as low as possible and the intake for this should be placed in a high pressure are on the hull The heated air should be discharged from the highest point and should be located in a low pressure area on the hull suck as the transom When sufficient ventilation is not provided too much heat can build up inside the engine comp...

Страница 184: ...ents at WOT MINIMUM Combustion Air Vent Area Per engine Up to 200 hp 18m3 min 400cm2 200 300 hp 20m3 min 450cm2 300 400 hp 25m3 min 500cm2 For engine combustion air only NOT total engine compartment ventilation requirement IMPORTANT The amount of vent area required according to boating standards NMMA ABYC etc and Coast Guard regulations for complete total engine compartment ventilation must includ...

Страница 185: ...UEL SYSTEM Fuel delivery system Fuel tank Fuel lines Additional fuel filter usage Fuel line fitting installation Fuel return fitting requirements Water separating fuel filter Fuel system temperature and pressure drop 184 184 185 186 186 187 187 188 ...

Страница 186: ...er diameter of at least 1 2 in 13 mm and must be fitted with a swan neck to prevent water from entering the tank x Fuel pickup should be at least 1 in 25 mm from the bottom of fuel tank to prevent picking up impurities x Return fuel line connection must flow freely into the top of the fuel tank must NOT have a pipe that exits at the bottom of the fuel tank Some additional consideration regarding t...

Страница 187: ...Installations It is best to use a fuel pickup and supply line for each engine If a single pickup and line is used line must not be smaller than 3 8 in 14 mm I D x Larger diameter than previously specified lines and fittings must be used on installations requiring long lines or numerous fittings x It is recommended that the exact route and length of the fuel lines be established at the first instal...

Страница 188: ...TATION FOR FUEL LINE FITTING INSTALLATION IMPORTANT The following information is provided to ensure proper installation of brass fittings or plugs installed into fuel pump or fuel filter base x Apply 592 Loctite Pipe Sealant on threads of brass fittings or plugs DO NOT USE TEFLON TAPE x Brass fittings or plugs should first be threaded into fuel pump or fuel filter base until finger tight x Fitting...

Страница 189: ...ust be no restriction on the return fuel system WATER SEPARATING FUEL FILTER The engine must be installed with the water separating fuel filter supplied with the engine The boat s fuel supply line connects to the fuel inlet fitting line connector on the filter base using a flexible fuel line A flexible fuel line must be used to absorb deflection when the engine is operated ...

Страница 190: ...reater demand on a fuel system and therefore cause a greater fuel pressure drop The design of the fuel system should always take into account the highest output engine offered in the boat Doing this will help prevent performance problems related to fuel supply Air temperature and the RVP Reid Vapor Pressure of the fuel also play an important role in fuel system performance Higher air temperature c...

Страница 191: ...l 189 Section 6 Engine Section 4 EXHAUST SYSTEM Important information Methods of measuring for raisers Straight edge method Through the hull Exhaust Exhaust connections Exhaust backpressure 190 191 191 193 194 195 ...

Страница 192: ...manship on the part of Marinediesel CAUTION Avoid severe engine damage Improper installation of the engine exhaust system or both may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine Install the engine and exhaust system according to Marinediesel instructions and procedures and according to recommended practices The exhaust system must be installed ...

Страница 193: ...ge and the top of the exhaust elbow 3 With the straight edge above the engine and parallel to the water measure the distance between the straight edge and the outside waterline 4 The difference between these two measurements is the exhaust elbow height above the water line Refer to Measuring Procedure and compare measurement to Marinediesel specifications Straight Edge Method For Measuring Exhaust...

Страница 194: ...w Height from Top of Elbow to Waterline Model Measurement All Models 13 in 330 mm Additional Requirements for Through The Hull and Through The Transom Exhaust System Applications Minimum Continuous Downward Slope Exhaust Hoses Collector Etc Model Application Measurement All 6q ...

Страница 195: ...han exhaust elbows at any point x The drop in the exhaust system must be continuously sloping so that a low spot does not exist at any point in the exhaust hose or pipe x The exhaust system on Marinediesel engines must have a minimum of 6q downward slope between the exhaust elbow outlet and the exhaust outlet of the boat x The exhaust system on Marinediesel engines must have a minimum of 4 in 102 ...

Страница 196: ...ter from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots which could eventually result in burned through exhaust hoses Exhaust hoses and or tubes must be correctly connected to exhaust elbows so that they do not restrict the flow of discharge water from exhaust elbow Incorrect Correct ...

Страница 197: ...ull or through the transom exhaust it is recommended that the boat s exhaust system be designed and tested for the highest horsepower engine to be offered in that boat Marinediesel specifies the following maximum backpressure which can be measured using the test outlined following Exhaust Back Pressure Specification Model Application Measurement All Engines Maximum 1 psi 7 kPa Ensure that both cyl...

Страница 198: ...ngine Section 5 COOLING SYSTEM General information Seawater supply and hose connections Through the hull or transom Seacock Seawater filter Seawater pump and bracket Drive belt routing Water heaters 197 197 198 199 199 200 201 202 ...

Страница 199: ...Hose Wire Reinforced Inner Diameter 1 1 4 in 32 mm Seacock Size Internal Cross Sectional Area Equal to or Greater Than Size Shown 1 1 4 in 32 mm Seawater Strainer Minimum Flow Rate 30 gallons per minute 114 liters per minute Important Engine Installed Flush System Sterndrive engines must have the flush system installed with the Y fitting located on the outlet side of the sea water pump The system ...

Страница 200: ...tional area equal to or greater than seawater inlet hose to prevent restricting water flow Pickup must be located on the boat in an area that permits an uninterrupted flow of water to the pickup Be sure to make hose connections with double hose clamps Typical Through The Hull Pickup Typical Through The Transom Pickup a Through The Hull Pickup b Seacock c Through The Transom Pickup d Water Flow IMP...

Страница 201: ...the seawater to flush or drain the engine or clean the sea strainer while boat is in the water Valve used must have an internal cross sectional area equal to or greater than hose to prevent restricting water flow Install valve in an area where it will be easily accessible Support valve adequately to prevent hose fatigue A brass ball or gate valve is required Typical Seacock Installation a Seacock ...

Страница 202: ... AND BRACKET The seawater pumps STD UV1 are installed and secured with hardware shown Screws torque to 30 lb ft 41 Nm Standard UV1 Commercial HV a Seawater Pump Bracket b Seawater Pump With Serpentine Belt Pulley c 8mm screws with washer a c b b a c ...

Страница 203: ...Owners Manual 201 Section 6 Engine DRIVE BELT ROUTING Barracuda With Power Steering SC With Power Steering Barracuda Without Power Steering SC Without Power Steering ...

Страница 204: ...he engine intake manifold to the engine water circulating pump NEVER close off or block the coolant flow to or from a heater All heater installations must be plumbed in series with the supply and return connections CAUTION Avoid engine overheating which could result in engine damage On models equipped with Closed Cooling an air pocket may form in the closed cooling system if some coolant is lost f...

Страница 205: ...Section 6 Engine Section 6 ELECTRICAL SYSTEM Electrical connections Battery Battery cables Accessories Electrical plug harness Warnings system and alarms Engine monitoring panel Wire color 204 204 205 206 207 208 208 209 ...

Страница 206: ...ossible Each engine requires it s own battery for normal operation Failure to do this will cause an unstable voltage source The alternator may not charge the battery properly if two engines are connected to a single battery Battery leads should not be reversed for example positive to negative RATING The various engine models have a variety of battery minimum rating requirements Failure to meet the...

Страница 207: ... ft 2 3 2 9m 00 70mm2 9 1 2 12 ft 2 9 3 7m 000 95mm2 12 15 ft 3 7 4 6m 000 95mm2 15 19 ft 4 6 5 8m 0000 120mm2 CONNECTIONS IMPORTANT Cable terminals must be soldered to cable ends to ensure good electrical contact Use electrical grade resin flux solder only Do not use acid flux solder as it may cause corrosion and a subsequent failure The positive battery cable is connected to the battery positive...

Страница 208: ...ANT Do not attach any accessory ground wires to engine block Accessory ground wires should only be attached to ground terminal on battery WIRE GAUGE Except for intermittent higher currents each low tension less than 50 Volts wiring circuit must not carry a current greater than the allowable amount specified for the wire gauge and temperature rating Refer to industry source material such as SAE J37...

Страница 209: ...entation wiring harness to be connected to the engine wiring harness The receptacle is designed for Marinediesel wiring A hose clamp is required to prevent separation and seal out moisture Install hose clamp at location shown All Models a Instrumentation Wiring Harness b Engine Wiring Harness Connector c Hose Clamp Location c a b ...

Страница 210: ...d a audible buzzer comes on when engine oil pressure is too low or engine coolant temperature is too high If warning system is activated immediately shut down the engine by turning the key to off position The installer will test warning system during Predelivery Preparation Refer to SECTION 7 Predelivery Engine monitoring panel a b c g h f k j i d e ...

Страница 211: ... Yes Yes Yes Yes Yes Yes Yes Yes Yes Typical Wire Color and Usage NOTE Color codes listed below may not apply to current production harnesses in all cases Color Code And Abbreviations Where Used BLACK All Grounds GRAY Tachometer Signal 4 pulses per engine revolution same as gasoline V8 YELLOW RED Starter Switch to Starter Solenoid RED Battery to Ignition Switch 12V PURPLE Ignition ON BROWN BLUE Wa...

Страница 212: ...delivery Preparation Battery connection Power steering Boat in the water test Engine Idle speed Wide open throttle test Important installation notes Predelivery checklist Cold weather or extended storage draining instructions 211 211 212 214 214 215 216 218 222 ...

Страница 213: ...the boat manufacturer s responsibility to perform these procedures or to make arrangement with the dealer to have these procedures completed Battery Connection IMPORTANT Engine electrical system is negative ground 1 Connect engine positive battery cable from the starter motor usually RED to positive battery terminal 2 Connect engine negative battery cable from engine block usually BLACK to negativ...

Страница 214: ...system CAUTION DO NOT RUN POWER STEERING DRY or pump will be damaged 1 Position drive unit so that it is straight back 2 Remove fill cap from power steering pump reservoir and check fluid level 3 Add fluid provided with power package as required NOTE When first starting engine be prepared to add fluid to pump a Fill Cap b Dipstick ...

Страница 215: ... oil fuel and exhaust leaks 8 Check power steering oil level a Turn steering wheel left port until it stops and continue to apply pressure If pump lugs engine rpm drops and or power steering pump tone changes check the following 1 Check for an obstruction between gimbal ring and gimbal housing and all moving steering components 2 Ensure steering lever is not contacting cutout in transom If contact...

Страница 216: ...ed with the boat out of the water Connect 32mm supply direct to impeller pump ENGINE IDLE SPEED Engine should idle at 600 700 rpm with engine at normal operating temperature If idle speed is incorrect proceed as follows 1 Disconnect the throttle cable from injection pump 2 Connect a shop tachometer to engine 3 Start engine and place the remote control lever in NEUTRAL gear idle position 4 Adjust i...

Страница 217: ... engine rpm in 200 rpm increments until engine reaches its maximum rated rpm To test if the correct propeller has been installed operate boat with normal load on board at WOT and check rpm with an accurate tachometer Engine rpm should be near top of the specified range so that under a heavy load engine speed will not fall below specifications If engine speed is too high replace propeller with a hi...

Страница 218: ...el feed hose line and that this is of adequate quality so that it doesn t get flat from the fuel feed pump suction If the fuel feed hose line get flat from suction the engine will loose rpm and performance instantly even if it may not run rough x You MUST use double hose clamps on all fuel line fittings to prevent air penetrating into the fuel system x Do NOT use Teflon tape or other to seal fuel ...

Страница 219: ...ed that the engine exhaust be run through the transom and NOT run exhaust through the sterndrive as this will lead to excessive backpressure x It is MANDATORY that all MARINEDIESEL engines are propped according to MARINEDIESEL recommendations Over propping of the boat induces excessive loading of the engine which will generate excessive exhaust temperatures and resulting reduction of engine longev...

Страница 220: ...at top of fuel tank no restriction Fuel leaks Seawater inlet valve open Water leaks Engine mounts tight Exhaust leaks Engine alignment Idle ______ RPM Battery fully charged Steering operation Electrical connections tight Forward Neutral Reverse gear operation Throttle shift and steering system fasteners tight Hot start after 20min with engine off heat soak Throttle opens fully and returns to idle ...

Страница 221: ...uel tank cleaned out and filled with diesel Re torque raiser bolts Battery cables area ___________mm2 First service after 2hrs see owners manual Height from top of exhaust raiser to water level ___________mm Remote oil filter gets warm showing that oil is circulating Engine room ventilation area ___________m2 Power trim operation Exhaust flaps to prevent water from entering engine Remote oil level...

Страница 222: ...st Not Applic Check Adjust Check before Running After on water test Double hose clamps on all exhaust hoses tightened Go through warranty and service information with customer Down angle on exhaust hose from raiser min 7deg Exhaust through drive Y N ________ ...

Страница 223: ...__________________ Propeller diam pitch make _____________________________________ Cruise speed mph knots rpm _____________________________________ WOT mph knots rpm _____________________________________ Installed by _____________________________________ Inspected by _____________________________________ Inspection date DD MM YY _____________________________________ _____________________ _________...

Страница 224: ...ent water from flowing back into seawater cooling system If boat is not fitted with a seacock water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and or boat As a precautionary measure attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine...

Страница 225: ...ull fitting If there is a leak on the raw water side before the impeller pump on the engine this may cause the impeller pump to draw air and the engine will overheat If there is a leak on the raw water side after the impeller pump this can lead to the bilge being flooded and or reduced cooling of the engine If there is a leak on the closed cooling system on the engine the coolant level will be red...

Страница 226: ...t any leaks If you do clean the engine make sure to cover the air filter to prevent water penetrating into the air intake of the engine Check belt tensioning system Each engine is equipped with a spring loaded belt tensioner The tensioner has a marking to show how much load is on the belt This load should very close to the maximum load on the marker or there will be belt slippage If there is not e...

Страница 227: ...e heat exchanger pressure cap And make sure you have the correct coolant level the level should be approx 10mm under maximum and just above the pipes inside the heat exchanger Also make sure you have a minimum of 30 antifreeze in the system even when running in tropical climates as this will lubricate the water pump and thermostats as well as act as a rust inhibitor ...

Страница 228: ... below for removing the oil but a manual or electric oil drain pump can also be used Oil change Procedure Step 1 Make sure the engine is at or close to operating temperature and shut down the engine Locate the engine oil dipstick on the port side of the engine clearly seen in yellow on the photo below ...

Страница 229: ...Owners Manual 227 Section 7 Engine Step 2 Remove the oil dipstick from the dipstick tube and insert the plastic tube from the oil drain pump or vacuum canister ...

Страница 230: ... not evacuate all the oil Drain all the oil from the engine Step 4 Remove the plastic fuel line and insert the oil dipstick back into the tube Change oil and filter and check on the dipstick that the correct level is achieved before starting the engine Then run the engine for a minute or to and verify the oil level top off if needed ...

Страница 231: ... oil Early commercial and all pleasure craft engines are equipped with a closed lubrication system for the supercharger This is a very specific high temp oil and the proper specification oil must be used Use a small suction pump or one of the plugs on the side of the supercharger gear housing to remove the oil flush out the housing with new oil if the oil is discolored Torque the side plug into pl...

Страница 232: ...percharger oil cooler 5 Return oil line from supercharger to engine oil pan Change air filter This is a very straight forward procedure that does not need further description Change Impeller There are two types of impeller pumps offered with Marinediesel s 6 5L engines One standard impeller pump and then the UV1 commercial high flow unit The two pumps use different impellers Both pumps are attache...

Страница 233: ... steps are very important x When replacing impeller always check the intake side of the oil cooler located on the lower port side of the engine block for debris Clean if needed x Always lubricate the new impeller with grease before installing it into the impeller pump housing x Do not forget to open the seacock before restarting the engine x Once the impeller is replaced and the engine is running ...

Страница 234: ...vailable but if you have questions on which to use please contact you local Marinediesel representative Change Serpentine belt You use a 3 8 wrench on the belt tensioner to loosen the tension on the belt and remove it The routing of the belt is shown on page 201 Change glow plugs The glow plugs need to be changed periodically to make sure the starting operation of the engine performs as it should ...

Страница 235: ...3 Section 7 Engine Change glow start relays and slave relay on port cylinder head The service book will inform you when to replace these relays Glow relay shown to the right and the slave relay to the left on port head ...

Страница 236: ...ylinder head 1 Glow relay 2 starter relay On back of port cylinder head Bosch slave relay shown in the photo above When replacing the relays make sure that there is no corrosion on the connectors and use some grease as corrosion protection when assembling 1 2 ...

Страница 237: ...ate the two alarm sensors on the engine x The temp warning sensor is located on the thermostat housing x The oil pressure is now located on the remote oil filter bracket but was previously located on the rear port side of the engine block where the oil lines from the remote oil filter fits to the engine block Step two would be to check that the sensors are operating correctly If the panel light an...

Страница 238: ...tivity lowest scale X1 is best 3 Connect one meter lead to a good ground point use the jumper wire if necessary 4 Momentarily test the meter connections by grounding to another point the second test lead The meter should read zero ohms 5 Remove the lead from the glow plug 6 Connect the non grounded multi meter lead to the glow plug Use the 1 jumper cable as required 7 The meter should read low res...

Страница 239: ...danger that low coolant in the heads might cause spot overheating Check condition of coolant hoses Check all coolant hoses for signs of wear of cracking replace if needed Idle speed adjustment There is an idle speed adjusting screw on the injection pump of the engine This screw can not be accessed when throttle position is idle so stop the engine and put throttle at 75 100 power either via throttl...

Страница 240: ...ee nuts again Check operation of crank case depression regulator The CDR cannister affectionately known as the tuna can is a Positive Crankcase Ventilation system for Diesels It provides regulated low vacuum about 1 at idle to 4 to 6 inches WC at full load from the engine air intake path to remove blow by gases from the crankcase and prevent oil leaks To verify operation you need to measure the cr...

Страница 241: ...aw water system Visual check and pressure test of intercooler Remove the intercooler core from the engine A visual check will show signs of corrosion if there have been any leaks Clean the intercooler and use a garden hose and the brass intercooler lid to pressure test the unit Have the water connected to one port and then block the other This normally provides approx 4bar for the pressure test wh...

Страница 242: ...olds as these will be in the way of obtaining access to the injectors Then loosen the injector line nut from the injector body Then bend the injector lines to the side carefully and remove the injectors Make sure you change the cupper seal ring when installing the new injectors ...

Страница 243: ...e torque all hose clamps Re torque clams as they can have loosened over time from vibration or deformation of rubber hoses Replace heat exchanger pressure cap The seal and spring has limited life as it will wear from frequent heat cycles ...

Страница 244: ...ck the alignment of the engine drive package at the same time Adjustment nut is turned counterclockwise to raise front of engine or clockwise to lower front of engine Typical Front Mount a Nut And Lock washer b Adjustment Nut c Adjustment Nut d Lag Screws Or Bolts e Tab Washer Change zink anodes In heat exchanger is placed one zink anode replace this unit ...

Страница 245: ...plication boat load or failure to follow instructions in applicable service and warranty information manuals or operation and maintenance manual 3 As applied to twin installation vessels continual operation of the vessel on only one engine in any condition other than an emergency situation 4 Use of an accessory or part not manufactured or sold by us 5 Operation with fuels oils lubricants or coolan...

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Страница 247: ...Serpentine Belt Change glow plugs Change glow relay Change antifreeze coolant in closed cooling system Check operation of engine warning system ground Check electrical connections for corrosion Check operation of gauges and charging Check operation of glow system Change thermostats Check condition of coolant hoses replace if needed Idle speed adjustment Check timing adjust if needed Check operatio...

Страница 248: ...nge Serpentine Belt Change glow plugs Change glow relay Change antifreeze coolant in closed cooling system Check operation of engine warning system ground Check electrical connections for corrosion Check operation of gauges and charging Check operation of glow system Change thermostats Check condition of coolant hoses replace if needed Idle speed adjustment Check timing adjust if needed Check oper...

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