Table of Contents
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Table of Contents
Summary of Contents for ILMORE 5.3L GDI
- Page 1 June 2019 OWNER’S MANUAL ILMOR Engines · 844-GO-ILMOR (464-5667) www.ilmor.com...
- Page 3 FORWARD WELCOME Ilmor Engines Ilmor Marine, LLC (Ilmor) is pleased to welcome you to boating OWNER’S MANUAL enjoyment available only through use of the extraordinary Ilmor engines. Ilmor is a recognized leader in the marine industry, having ILMOR ENGINES originated through championship-caliber, high-performance engines. Ilmor’s line of engines deliver the necessary power to plane with pulse-pounding quickness without sacrificing reliability or smoothness.
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Page 4: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ................................6 INTRODUCTION TO MANUAL ..............................6 SAFETY ................................... 7 SAFETY INSTRUCTIONS ................................7 DANGERS, WARNINGS, CAUTIONS, AND NOTICES ....................................8 GENERAL SAFETY CONCERNS ..............................8 SAFETY NOTICES ..................................9 FUNCTIONS AND DESCRIPTIONS ........................... 12 EXHAUST SYSTEM ..................................12 FUEL SYSTEM .....................................12 COOLING SYSTEM ..................................12 Open Cooling System ................................13 Closed Cooling System ................................13... - Page 5 TABLE OF CONTENTS OPERATION ................................19 FUELING THE ENGINE ................................19 Fuel Requirements ..................................20 Oxygenated Gasoline or Gasoline Containing Alcohol ......................20 When Boat Is Placed Out Of Service ............................21 Fuels Outside the United States and Canada ......................................21 BEFORE EACH USE ...................................21 Check Engine Oil (Cold) ................................21 Check Sea Strainer ..................................22 Check Coolant Level .................................23...
- Page 6 TABLE OF CONTENTS START ENGINE ....................................30 Pushbutton Start ..................................30 Key Switch Start ..................................30 SHIFT GEARS ....................................31 STOP THE BOAT ..................................31 OTHER CONSIDERATIONS ...............................32 HEAVY DUTY USAGE .................................32 COMMERCIAL USAGE................................32 MAINTENANCE ................................33 MAINTENANCE SCHEDULE ..............................33 CHECK ENGINE OIL (WARM) ..............................35 CHECK TRANSMISSION FLUID/OIL LEVEL ..........................35 SERPENTINE BELT ..................................35 Inspect Serpentine Belt ................................35...
- Page 7 TABLE OF CONTENTS EMISSIONS ................................. 40 EMISSIONS CONTROL SYSTEM INFORMATION .....................................40 CALIFORNIA AIR RESOURCE BOARD (CARB) STAR LABEL ....................40 CARB Overview ..................................40 Environmental Label ..................................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...
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Page 8: Introduction
INTRODUCTION INTRODUCTION TO MANUAL Please read Owner’s Manual completely prior to operating engine and boat for the first time. The Owner’s Manual contains information critical for safe operation and maintenance of your marine products purchased from Ilmor that is required to activate and keep the limited warranty statement in effect throughout the applicable warranty period. -
Page 9: Safety
SAFETY SAFETY INSTRUCTIONS For details on safety rules and regulations in the United States, contact your local office of the Occupational Safety and Health Administration Prior to operating boat for the first time, operators MUST read entire (OSHA). Owner’s Manual. Reread manual prior to first operation at beginning Failure to adhere to and comply with safety dangers, warnings, of the boating season. -
Page 10: Dangers, Warnings, Cautions, And Notices
SAFETY DANGERS, WARNINGS, CAUTIONS, GENERAL SAFETY CONCERNS AND NOTICES DANGER! Always avoid exhaust areas and engine compartment during the venting of engine exhaust. Engine DANGER, WARNING, CAUTION and NOTICE are used throughout this manual to highlight important information. Be certain that the exhaust emits carbon monoxide, which is colorless, odorless meanings of these alerts are understood by all who work on or near and poisonous even in small concentration. -
Page 11: Safety Notices
SAFETY Onboard personnel must be vigilant whenever the engine is running with engine compartment open. Avoid all moving parts. When possible, WARNING! Always use genuine Ilmor replacement parts adjustments to the engine or anything accessible from the engine intended for the engine. The electrical and ignition components compartment while the engine is running should be performed by an have been designed to comply with U.S. - Page 12 SAFETY WARNING! When servicing fuel system components, WARNING! Operating, servicing, and maintaining a always have an appropriately-rated fire extinguisher nearby and recreational marine vessel can expose you to chemicals adequate workspace ventilation. Failure to do so could result in including engine exhaust, carbon monoxide, phthalates, and fire or carbon monoxide poisoning, which could result in serious lead, which are known to the State of California to cause cancer injury or death.
- Page 13 SAFETY NOTICE: The raw water pump system must remain free and clear of debris at all times. Operating the engine with a blocked raw water pump may cause overheating conditions, resulting in damages to powertrain components. Be sure to inspect/replace the raw water pump regularly.
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Page 14: Functions And Descriptions
FUNCTIONS AND DESCRIPTIONS EXHAUST SYSTEM FUEL SYSTEM Ilmor engines are equipped with wet marine exhaust systems where Ilmor gasoline engines are designed with either a multi-port injection raw water enters exhaust elbows (downturn adapters) and mixes with (MPI) or a gasoline direct injection (GDI) fuel delivery system. Ilmor exhaust gases. -
Page 15: Open Cooling System
FUNCTIONS AND DESCRIPTIONS Ensure engine seacock remains clear of debris at all times. Even small NOTICE: Marine growth occurs in brackish, salt water, and even in amounts can clog or block the pick-up located beneath the boat. The fresh (salt-free) water. It is important to flush the cooling system with engine seacock MUST have an uninterrupted input of water whenever fresh tap/treated water after each use. -
Page 16: Quick Drain Procedure (Gdi-S Models)
FUNCTIONS AND DESCRIPTIONS Quick Drain Procedure (GDI-S Models) CAUTION! Not opening the flush port cap for the siphon This system allows the operator to drain the engine raw water system. break may result in unwanted water flow into the bilge Ilmor recommends performing this procedure after each use of the compartment. -
Page 17: Flushing Procedure
FUNCTIONS AND DESCRIPTIONS Flushing Procedure ELECTRICAL SYSTEM 1. Pressurized winterizing kits will consist of a container, a CAUTION! Any repair, replacement, and/or installation corresponding flushing attachment for the engine seacock inlet, and of an electrical system component must meet or exceed the an attaching hose. -
Page 18: Power Distribution Module (Pdm) - Custom Inboard Series
FUNCTIONS AND DESCRIPTIONS Electronic Power Distribution Module WARNING! Always connect the positive (+) battery cable (ePDM) first. After the positive cable is connected, then the negative (-) battery cable can be attached. This minimizes the possibility of The ePDM is mounted on the rear of the engines. The ePDM replaces electrical contact. -
Page 19: Engine Sensors
FUNCTIONS AND DESCRIPTIONS ENGINE SENSORS The alarm activation will display if the following conditions occur: • Water temperature (Engine Coolant Temperature Higher than The engine is equipped with many sensors. These sensors provide Expected) performance information such as engine speed, engine coolant temperature, engine oil pressure, and much more. -
Page 20: Oil Pressure
FUNCTIONS AND DESCRIPTIONS Oil Pressure Alarm appears if the engine oil pressure falls below recommended value for current engine speed. If this 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. -
Page 21: Operation
OPERATION FUELING THE ENGINE WARNING! Inspect entire fuel system for leaks and/or deterioration prior to operation, especially after substantial DANGER! Never start engine if gasoline odor is present or if periods of non-use or storage. Ensure inspection includes gasoline leaks appear along the fuel line, fuel tank, in the bilge, fuel tank, fuel lines, fuel pump, regulator, fuel rails, carbon or around the engine. -
Page 22: Fuel Requirements
Higher-octane fuel causes less knock for the ignition system to process and adjust timing. All Ilmor engines (5000MPI, 6.0L MPI/-S, 7.4L MPI/-S, 5.3L GDI/-S, Poor-quality or old fuels can cause problems such as loss of and 6.2L GDI/-S) require a minimum of 87 octane gasoline. It is highly performance, rough idling, hard starting, and hesitation. -
Page 23: When Boat Is Placed Out Of Service
OPERATION Fuels Outside the United States and The fuel tank level should NEVER be below 1/4 tank full. In the event the engine runs out of fuel, cycle ignition key 5 times and attempt to Canada start engine. If the engine fails to start and run, repeat this process again up to 3 times. -
Page 24: Check Sea Strainer
OPERATION Recommended Cold oil level NOTICE: Ensure seacock is in the OPEN position before operating DO NOT OVERFILL! boat. If not, engine will overheat and raw water pump impeller could be compromised, causing severe engine problems. Ensure sea strainer cap/lid is installed correctly and O-ring is not pinched. Failure to do so will cause air to be introduced into the system and could cause the raw water impeller to be compromised, causing severe Check Sea Strainer... -
Page 25: Check Coolant Level
OPERATION Check Coolant Level MPI-S series only closed-cooling reservoir cap and tank WARNING! Contents under pressure! Do not remove the cooling system cap when the engine is warm. Allow ample time for engine to cool before checking coolant level. Wear proper personal protective equipment when checking coolant. -
Page 26: Check Power Steering Fluid (-S Models)
OPERATION Check Power Steering Fluid (-S Models) CAUTION! Check power steering fluid before starting engine, or allow engine to cool after shutting down. Failure to do so may MAX Mark result in burns to personnel from hot engine components. MIN Mark This procedure applies to engines equipped with power steering systems. -
Page 27: Check Battery Connections And Hold-Downs
OPERATION Check Battery Connections and 3. Check that battery post connections are clean and tight. If not, see Inspect and Clean Battery Connections and Hold-Downs section in Hold-Downs the maintenance chapter of this manual. WARNING! Keep sparks, flames, and smoking materials Battery post connections away from battery charging area. -
Page 28: Inspect Engine And Engine Cables
OPERATION NOTE: The voltmeter is the best indication of the state of the battery, but it is not CHECK FOR KINKS, WEAR AND INTERFERENCE OF THROTTLE foolproof. Even if the voltmeter indicates the battery is producing current while running AND SHIFT CABLES the boat, yet during a previous outing there was reason to suspect a problem with the Follow each cable back under the floorboards and feel for any kinks or battery or batteries, then an issue may still exist. -
Page 29: Inspect Fuel And Exhaust Systems For Leaks
OPERATION Inspect Fuel and Exhaust Systems for not warm up; it must warm up to open the thermostat, which is required for proper flushing. If the engine will not warm up, remove Leaks thermostat and flush engine with fresh water for 5 minutes while cycling the engine speed from idle to 2,000 rpm in 10-second DANGER! If at any time during operation there is an intervals. - Page 30 OPERATION Although the Ilmor powertrain may have been lake-tested by the boat WARNING! Never operate engine without adequate and manufacturer, the break-in period starts when the retail consumer takes uninterrupted water flowing through the cooling system. This possession of the boat and follows the instructions provided in this requires the boat to be in an operational-sized body of water or Owner’s Manual.
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Page 31: First Hours Of Operation (First 25 Hours)
OPERATION First Hours of Operation (First 25 Hours) After First Hours Of Operation (After First 25 Hours) DANGER! Prior to operating bilge, open engine compartment 1. After engine break-in and oil change have been completed, engine and check for fumes, leaks or presence of fluids. If clear, operate may be operated more continuously at speed, but never beyond the bilge blower for at least 4 minutes before starting engine, and maximum allocated speed. -
Page 32: Start Engine
OPERATION 1. After performing all the checks and inspections outlined in this 2. Move throttle/shift control lever to neutral position. This allows Owner’s Manual, lift the engine compartment cover. electronic controls within the engine to automatically and correctly meter fuel and air flows. DANGER! Open engine compartment and check for fumes, leaks or presence of fluids in bilge before starting engine. -
Page 33: Shift Gears
OPERATION SHIFT GEARS NOTICE: If engine fails to crank, or cranks slowly, check engine Ensure engine is at normal operating temperature prior to placing boat battery voltage. If engine battery voltage is below 11.0V (Volts) when in gear. the ignition key is turned to the ON position, the available voltage is When shifting gears, always move the throttle/shift control lever too low to effectively crank/start engine. -
Page 34: Other Considerations
OPERATION OTHER CONSIDERATIONS NOTICE: The following steps do not take into account effects of area Wide-open throttle exists to allow boaters to get out of dangerous conditions such as tides, currents, winds, weather, and/or passing encounters or situations, but it represents the upper limit of the engine’s wakes of other nearby vessels. -
Page 35: Maintenance
MAINTENANCE MAINTENANCE SCHEDULE Ilmor recommends that maintenance is performed by an authorized Ilmor service center. Service technicians there have proper equipment, training, and resources to best meet service needs. Please note that routine maintenance is not covered by the Ilmor Limited Warranty. For details, consult limited warranty statement. - Page 36 MAINTENANCE Scheduled Maintenance Chart Before Annually First Every Every Every Every Every Every Every Every Every Every Each (Season 50 hrs 75 hrs Start) Years Years Years Engine Service Item Maintenance procedures are best performed by a certified Ilmor service center I = INSPECT R = REPLACE Fuel/Water Separator...
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Page 37: Check Engine Oil (Warm)
MAINTENANCE CHECK ENGINE OIL (WARM) CHECK TRANSMISSION FLUID/OIL LEVEL An accurate engine oil level reading will occur only after the engine has Transmission requires lubrication to function properly. Your dealer can run for at least 5 minutes at idle. Run engine while boat is in body of verify the type of transmission in the boat. -
Page 38: Replace Serpentine Belt
MAINTENANCE 3. Too-loose or too-tight tension is indicative that it is time for operations, and strand the boaters. Therefore, this maintenance function should be service on the belt. This should be done by a trained Ilmor service taken very seriously. technician. -
Page 39: Clean Engine Compartment And Prevent Corrosion
MAINTENANCE CLEAN ENGINE COMPARTMENT AND NOTICE: Always properly clean the engine and transmission if PREVENT CORROSION exposed to salt water. Exposure to salt water causes corrosion, The engine compartment should receive a good, general cleaning of leading to significant damage to metal, including stainless steel. If the interior as well as the engine and transmission exteriors. -
Page 40: Storage And Winterization
MAINTENANCE STORAGE AND WINTERIZATION 5. Remove all corrosion material from the boat, wipe clean and dry the battery with a disposable rag. Note that this is a generic cleaning Proper storage and/or winterization preparations are just as important method. Battery manufacturers may specify other methods of as how a powertrain is maintained in use. -
Page 41: Fuel System Treatment
MAINTENANCE Fuel System Treatment NOTICE: It is extremely important to monitor gaseous emissions Boats that are going to be stored for extended periods (more than 30 throughout the life of the engine. To maintain emissions levels within days) or winterized should have special treatment for the fuel system. the certified standards, the owner/operator is responsible for ensuring Always follow the boat owner’s manual on how to properly winterize the that engine maintenance is performed as described in this Owner’s... -
Page 42: Emissions
EMISSIONS ECI label Beginning January 1, 2009, any boat sold or registered 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 –... -
Page 43: Environmental Label
EMISSIONS Environmental Label OBD-M All Ilmor engines are equipped with OBD-M to comply with 2009 NOTICE: The dealer is responsible for the Environmental Label (hang and later California-mandated OBD-M specification. The Malfunction tag). The dealer must mark the correct box on each hang tag to match Indicator Lamp (MIL) or a Check Engine warning will appear on the the Star Label on the engine and the boat. -
Page 44: California And U.s. Epa Emission Control Warranty Statement
EMISSIONS CALIFORNIA AND U.S. EPA EMISSION Warranty Terms CONTROL WARRANTY STATEMENT Select electronic emission-related control parts from model year 2020 and later sterndrive/inboard engines are warranted for 3 years or 480 Warranty Rights and Obligations hours, whichever first occurs. CARB, U.S. EPA, and Ilmor are pleased to explain the emission control Select mechanical emission-related components are warranted for 3 system warranty on your 2013 model year and later sterndrive/inboard years or 480 hours, whichever first occurs. -
Page 45: Owner Warranty Responsibilities
EMISSIONS Owner Warranty Responsibilities General Emissions Warranty Coverage The owner of the sterndrive/inboard engine is responsible for Ilmor must warrant that the engine is: performing required maintenance listed in the owner’s manual. Ilmor 1. Designed, built and equipped so as to conform with all applicable recommends retaining all receipts covering maintenance on the regulations adopted by the CARB pursuant to its authority in sterndrive/inboard engine to document compliance with scheduled... -
Page 46: Mechanical Emission-Related Components Warranty
EMISSIONS Electronic Emission-Related Control DISCLAIMER: Parts Warranty This warranty is applicable only where the California and U.S. EPA emission control system warranty regulation is in effect. At the discretion of Ilmor, the use of add- on(s) or modified part(s) Systems Covered by this Parts Description not exempted by the CARB or the U.S. -
Page 47: Direct Emission-Related Control Parts Warranty
EMISSIONS Direct Emission-Related Control Parts Warranty Systems Covered by this Parts Description Warranty Catalytic Converter Catalytic converter(s) Oxygen sensor Evaporative System Low-permeation (non-metal) fuel hose(s) · 844-GO-ILMOR (464-5667) www.ilmor.com... -
Page 48: Troubleshooting
TROUBLESHOOTING The following chart is offered as assistance in identifying and correcting minor issues that may occur. Problems are listed in the order of most-likely to least-likely of occurrence. Not all possible problems, causes and solutions are listed here. When experiencing problems, check surroundings before shutting down the engine. Stopping the power suddenly would result in placing other boats and boaters in jeopardy, continue until it is safe to slow or stop, and analyze the situation. - Page 49 TROUBLESHOOTING Problem Possible Cause Potential Solution Poor boat performance. Weak or faulty ignition components. See authorized Ilmor service center. Contaminated fuel. Drain fuel and replace fuel filter. See authorized Ilmor service center. Plugged spark arrestor. Clean the spark arrestor. High intake air temperature. Verify engine bay is vented adequately.
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Page 50: Specifications
SPECIFICATIONS INBOARD ENGINES Engine Model 5.3L GDI 6.0L MPI 6.2L GDI 7.4L MPI Number of Cylinders 365 HP (272 kW) 373 HP (278 kW) 430 HP (321 kW) 522 HP (390 kW) Power* @ 5400 RPM @ 5200 RPM @ 5400 RPM... - Page 51 SPECIFICATIONS INBOARD ENGINES Engine Model 5.3L GDI 6.0L MPI 6.2L GDI 7.4L MPI Coolant Type Propylene Glycol/Water 50/50 Mix (if equipped) Coolant Capacity 5 gal (18 L) to 6 gal (22 L) (if equipped) Normal Operating 160°F (71°C)- 130°F (54°C)- 160°F (71°C) -...
- Page 52 SPECIFICATIONS ONE-DRIVE ENGINES ® Engine Model 5.3L GDI-S 6.0L MPI-S 6.2L GDI-S 7.4L MPI-S Number of Cylinders 365 HP (272 kW) 382 HP (285 KW) 430 HP (321 kW) 483 HP (360 KW) Power* @ 5400 RPM @5200 RPM @ 5400 RPM...
- Page 53 SPECIFICATIONS CUSTOM INBOARD ENGINES Engine Model 5.3L GDI-S 6.0L MPI-S 6.2L GDI-S Number of Cylinders 320 HP (239 KW) 382 HP (285 KW) 430 HP (321 kW) Power* @ 5000 RPM @5200 RPM @ 5600 RPM 370 ft-lb (502 NM)
- Page 54 SPECIFICATIONS SERVICE LOG Service Date Date Date Date Date Date Engine Coolant Engine 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 ®...
- 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...