PSI 8.8L GASOLINE Operation And Maintenance Manual
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PSI 8.8L GASOLINE Operation And Maintenance Manual

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Power Solutions International, Inc
8.8L GASOLINE For On-Road Applications
Engine Operation and Maintenance Manual
201 Mittel Dr.
Wood Dale, IL 60191
Power Solutions International, Inc.
36100026 – Rev 2
US EPA & CARB HD-SI Certification
May 2019

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  • Page 1 Power Solutions International, Inc 8.8L GASOLINE For On-Road Applications Engine Operation and Maintenance Manual 201 Mittel Dr. Wood Dale, IL 60191 Power Solutions International, Inc. 36100026 – Rev 2 US EPA & CARB HD-SI Certification May 2019...
  • Page 2 IMPORTANT The information, specifications, and illustrations contained in this manual are based on data that was current at the time of publication. Power Solutions International, Inc. reserves the right to make changes and/or improvements at any time without notification, liability, or without applying those changes or improvements to vehicles previously manufactured and/or sold. NOTICE Be advised that this motor vehicle may be equipped with computer/recording devices.

  • Page 3: Table Of Contents

    ABLE OF ONTENTS FOREWORD ....................................2 SAFETY INFORMATION ................................4 WARRANTY ....................................10 EPA and CARB Emission System Warranty ..............................10 Manufacturer's Warranty Coverage ................................10 Owner's Warranty Responsibilities ................................11 Warranty Exclusions ...................................... 12 SECTION 1 – ENGINE SYSTEMS ............................... 13 Engine Serial Number .....................................
  • Page 4 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT ................30 Fuel ........................................... 31 Use of Seasonal Fuels ....................................31 Prohibited Fuels ......................................31 California Fuel Requirements ..................................31 Fuels in Foreign Countries .................................... 32 Fuel Additives ........................................ 32 E85 Fuel ........................................
  • Page 5 Oil Pressure Gauge ....................................... 37 SECTION 4 – ENGINE OPERATION ............................38 Pre-operation Checklist ....................................39 Starting the Engine ......................................40 Starting Engine After Running Out of Fuel ..............................41 Emergency Starting ......................................42 Operation .......................................... 43 Idle Speed ........................................43 Cold Weather Operation ....................................
  • Page 6 SECTION 6 – LONG TERM STORAGE ............................57 General Information ......................................58 SECTION 7 – SERVICE RECORDS ............................. 60 Maintenance Service Record ..................................61 Daily Care and Report ..................................... 65 APPENDIX ....................................68 Engine Specifications ..................................... 69...
  • Page 7 FOREWORD P a g e...

  • Page 8: Foreword

    This manual includes necessary information and specifications does not cover vehicle or equipment maintenance procedures. for operators to operate and maintain the PSI 8.8L Gasoline When referring to the left-hand or right-hand side of the engine. Contact your dealer for more information.
  • Page 9 SAFETY INFORMATION P a g e...

  • Page 10: Safety Information

    SAFETY INFORMATION Safety Information Safety Instructions Work Area This manual provides general and specific maintenance procedures essential for reliable engine operation and your safety. • Keep work area clean, dry, and organized. Since many variations in procedures, tools, and service parts exist, Keep tools and parts off the floor.
  • Page 11 SAFETY INFORMATION Gasoline Safety Specifications Specification Value Unit Initial Boiling Point @14.7 psi 399 (204) °F (°C) Weight per Gallon @ 60°F 6.24 (2.83) lbs/gal (kg/L) Ignition Temperature in Air 536 (280) °F (°C) Air Fuel Ratio by Mass 14.7:1...
  • Page 12 • operating engine. Use an OSHA approved blow gun. Limit blow gun air • pressure to 30 psi (207 kPa). Do not run engine with unprotected air inlets or exhaust • openings. If unavoidable for service reasons, put protective Wear safety glasses or goggles.
  • Page 13 SAFETY INFORMATION Tools Refueling WARNING: Fuel vapors and fuel fires burn violently and can Make sure all tools are in good condition. • cause injury or death. Make sure all standard electrical tools are grounded. • To help avoid injuries to you and others, read and follow all •...
  • Page 14 SAFETY INFORMATION Refueling (cont.) General Safety Instructions • When replacing the fuel cap, follow OEM recommendations on tightening procedure. WARNINGS: • Keep all sources of ignition away from gasoline vehicles The diagnostic system can determine if the fuel cap has •...
  • Page 15 WARRANTY P a g e...

  • Page 16: Warranty

    Solutions EPA and CARB Emission System Warranty International, Inc. are pleased to explain the emission control system warranty on your PSI 8.8L Gasoline engine. In California, WARRANTY PERIOD new motor vehicles must be designated, built and equipped to meet the State's stringent anti-smog standards. Power Solutions Government agencies including the United States Environmental International, Inc.

  • Page 17: Owner's Warranty Responsibilities

    WARRANTY Federal Emission System Warranty (cont.) All receipts and failed parts must be kept in order to receive compensation for warranted repairs reimbursable due to an Owner's Warranty Responsibilities emergency. As the truck owner, you are responsible for the performance of If you have any questions regarding your warranty rights and the required maintenance listed in your Operation and responsibilities,...

  • Page 18: Warranty Exclusions

    • Repairs to engines used for re-powering on-road vehicles. • PSI may deny any claims that in their sole discretion are the result of misapplication of the engine or part. • All consequential expenses, including, but not limited to, those resulting from equipment failure such as lodging, food, •...

  • Page 19: Section 1 - Engine Systems

    – SECTION 1 ENGINE SYSTEMS 13 | P a g e...

  • Page 20: Engine Serial Number

    SECTION 1 – ENGINE SYSTEMS Engine Serial Number The engine serial number can be found in two locations. The serial number label will be located on the right-hand side valve cover as shown in Figure 2. The number will also be stamped on the left-hand side of the engine, near the flywheel as shown in Figure 3.

  • Page 21: Engine Emission Label

    SECTION 1: ENGINE SYSTEMS Engine Emission Label Engine Accessories The U.S. Environmental Protection Agency (EPA) exhaust The following engine parts may have manufacturer's emission label is attached to the plate on top of the intake labels or identification plates: manifold as shown in Figure 5. The EPA label typically includes the following: •...

  • Page 22: Engine Specification

    Engine Description The camshaft is a one-piece billet design supported by 5 The PSI 8.8L Gasoline engine is a pushrod style V8 engine bearings pressed into the engine block. The camshaft is driven that has been designed to produce EPA compliant emissions off the crankshaft by the timing chain and gears.
  • Page 23 Fuel lines are constructed to Fuel System withstand maximum fuel system pressure, exposure to fuel The PSI 8.8L Gasoline engine is equipped with a returnless additives, and changes in temperature. Heat resistant rubber on-demand fuel system design. The fuel pressure regulator is...
  • Page 24 – SECTION 1 ENGINE SYSTEMS Fuel Level Sensor Engine Description (cont.) The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the Fuel System – Fuel Tank and Fuel Pump Module Assembly fuel level.
  • Page 25 – SECTION 1 ENGINE SYSTEMS Fuel System - Injectors and Fuel Rails Fuel Filter The fuel filter is contained in the fuel tank fuel pump module The fuel injector assembly is a solenoid device controlled by assembly inside the fuel tank. The paper filter element of the fuel the engine control module (ECM) that meters pressurized fuel filter traps particles in the fuel that may damage the fuel injection to a single engine cylinder.
  • Page 26 – SECTION 1 ENGINE SYSTEMS Engine Description (cont.) Figure 7: Fuel System Layout (For Reference Only) 20 | P a g e...

  • Page 27: Engine Features

    Engine Component Protection System speed, final drive ratio, and tire size revolutions per minute. The The PSI 8.8L Gasoline is designed to protect all systems from PSI PowerLink tool can be used to modify any changes that damage by monitoring data such as engine temperature, oil occur to these systems.

  • Page 28: Engine Related Optional Features

    Programming System (VEPS) in order to allow specific ECM PSI Power Link Password Protection parameters to be modified when necessary. These modifications can be made with the PSI PowerLink tool or by a This feature will prevent unauthorized users from changing any certified service center.
  • Page 29 Cold Start Assist • Mobile Variable Speed - Permits the operator to select The PSI 8.8L Gasoline engine will have an optional cold start a desired variable speed for moving or stationary PTO assist system. This system will be supplied with both a plug-in operations.
  • Page 30 Reverse. These options can be enabled by programmable parameters within the Engine Control Module (ECM). These changes can be made with a PSI Powerlink Tool or by a Certified Service Center. 24 | P a g e...

  • Page 31: Component Location - Top

    SECTION 1 – ENGINE SYSTEMS Component Location – Top Figure 8 - Typical Top View 1. Oil Cooler 2. Ignition Coils 3. Compressor 4. Throttle Body 5. Alternator Mounting Location 6. Oil Fill Cap 7. Dipstick and Tube 8. Engine Control Module (ECM - Chassis Mounted) 9.

  • Page 32: Component Location - Front

    – SECTION 1 ENGINE SYSTEMS – Component Location Front Figure 9 - Typical Front View 1. Engine Control Module (ECM - Chassis Mounted) 2. Alternator Mounting Location 3. Throttle Body 4. Power Steering Pump and Pulley 5. Compressor 6. Cam Position Sensor 7.

  • Page 33: Component Location - Left

    SECTION 1 – ENGINE SYSTEMS Component Location – Left Figure 10 - Typical Left View 1. Compressor 2. Engine Control Module (ECM - Chassis Mounted) 3. Ignition Coils 4. Oil Cooler 5. Leads to Post-Cat O2 Sensors 6. Crank Position Sensor 7.

  • Page 34: Component Location - Right

    – SECTION 1 ENGINE SYSTEMS – Component Location Right Figure 11 - Typical Right View 1. Oil Cooler 2. Right Rear Lifting Eye 3. MAP Sensor 4. Engine Control Module (ECM - Chassis Mounted) 5. Oil Fill Cap 6. Alternator Mounting Location 7.
  • Page 35 SECTION 1 – ENGINE SYSTEMS Component Location – Rear Figure 12 - Typical Rear View 1. Compressor 2. Left Rear Lifting Eye 3. MAP Sensor 4. Oil Cooler 5. Right Rear Lifting Eye 6. Dipstick and Dipstick Tube 7. Right Side Knock Sensor 8.
  • Page 36 – SECTION 2 REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT 30 | P a g e...

  • Page 37: Fuel

    If this occurs, see your dealer for service. California Fuel Requirements Use of Seasonal Fuels The 8.8L Gasoline engine is certified to meet California Emissions Standards. it is designed to operate on fuels that meet Use summer and winter fuels in the appropriate season. The California specifications.

  • Page 38: Fuels In Foreign Countries

    E85 Fuel The use of E85 fuel or fuel mixtures with an ethanol content greater than 10% are not approved for use in the 8.8L Gasoline engine. The maximum ethanol content for fuels that can be used in the 8.8L Gasoline engine is 10%.

  • Page 39: Engine Oil

    COOL® meets ASTM D 3306 standards and is recommended for properties. use in automotive applications. All oil used in the PSI 8.8L Gasoline engine must meet the The PSI 8.8L Gasoline engine requires the use of a 50/50 Dexos1® specification and display the green Dexos1® logo.

  • Page 40: Section 3 - Instruments, Indicators, And Switches

    – SECTION 3 INSTRUMENTS, INDICATORS, AND SWITCHES 34 | P a g e...

  • Page 41: Instrument Panel Gauge Cluster

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Instrument Panel Gauge Cluster Maintenance Lamp During engine starts and engine operation, gauges If equipped, the Maintenance lamp will illuminate in conjunction and indicator lamps should be checked periodically. with other warning lights or general text and warning messages. It may be accompanied by an audible alarm to indicate an alert Gauges may vary with vehicle applications.

  • Page 42: Red Stop Lamp (Rsl)

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Red Stop Lamp (RSL) CAUTION: To prevent engine damage, shut down engine immediately, if the RED Stop Lamp flashes The RED Stop Lamp indicates that a severe fault condition exists and the engine should be shut down as soon as it is safe to do so.

  • Page 43: Gauges

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Gauges Oil Temperature Gauge Typical Water Temperature Gauge The engine oil temperature gauge indicates the oil temperature of The water temperature gauge indicates the temperature of the engine. coolant in the cooling system. The gauge operates only when the Oil Pressure Gauge ignition switch is turned to ON.

  • Page 44: Section 4 - Engine Operation

    – SECTION 4 ENGINE OPERATION 38 | P a g e...

  • Page 45: Pre-Operation Checklist

    – SECTION 4 ENGINE OPERATION Pre-operation Checklist GOVERNMENT REGULATION: Engine fluid (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluid and other contaiminated materials (e.g. filters, rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, Figure 14: Oil Level Gauge (typical) and other contaiminated materials according to applicable regulations.

  • Page 46: Starting The Engine

    – SECTION 4 ENGINE OPERATION Starting the Engine 1. Set parking brake and shift transmission to Park (P) or Neutral (N). To restart the engine when the vehicle is already moving, use N (Neutral) only. WARNING: To prevent personal injury or death, do not CAUTION: Do not try to shift to P (Park) if the vehicle is use ether, gasoline, gasohol, or other starting aids.

  • Page 47: Starting Engine After Running Out Of Fuel

    – SECTION 4 ENGINE OPERATION Starting the Engine (cont.) During normal engine operation the low oil pressure lamp will illuminate if minimum oil pressures are not met. If the NOTE: If the engine fails to start after 20 seconds of lamp remains illuminated for an extended period of time a cranking, do the following: derate may occur.

  • Page 48: Emergency Starting

    – SECTION 4 ENGINE OPERATION Emergency Starting WARNING: To prevent personal injury or death, always connect jumper cable for positive battery terminals first. WARNING: To prevent personal injury or death, do WARNING: To prevent personal injury or death, do not not use ether starting fluid to start the engine.

  • Page 49: Operation

    – SECTION 4 ENGINE OPERATION Operation 1. Before operating the engine at 32°F (0°C) or lower, follow pre- operation checks and check or service the following: Idle Speed Correct battery size • • Full battery charge and charging system operation WARNING: To prevent personal injury or death, provide ventilation when operating an engine in a •...

  • Page 50: Hot Weather Operation

    – SECTION 4 ENGINE OPERATION Operation (cont.) Hot Weather Operation 1. Before operating the engine above 90°F (32°C), follow pre-operation checks and check or service the following: Full battery charge and charging system operation • • Condition of other electrical equipment Cooling system leaks •...

  • Page 51: Engine Warning Protection System (Ewps)

    – SECTION 4 ENGINE OPERATION Operation (cont.) Engine Warning Protection System (EWPS) • Coolant Temp Warning Threshold EWPS warns the operator of engine conditions that can damage the engine. Optional engine shutdown is available, contact your • Coolant Temp Critical Threshold dealer for information.

  • Page 52: Heavy Duty On Board Diagnostics (Obd Hd) Overview

    Heavy Duty On Board Diagnostics (OBD HD) Overview RSG is the top vehicle speed the ECM allows. RSG can be set from factory or with the PSI Powerlink using VEPS. A Reverse The OBD HD system uses many individual pre-programmed Speed Governor will also accompany the RSG settings, this “monitors”...

  • Page 53: Section 5 - Maintenance Schedule And Service Procedures

    – SECTION 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 47 | P a g e...

  • Page 54: Maintenance Schedule

    Engine Oil (7.5 quarts) DEXOS 5W-30 DEXOS 5W-30 PSI - 80000983 Engine Oil Filter DEX-COOL 50/50 Engine Coolant DEX-COOL 50/50 * or any PSI approved coolant. PSI – 80000808 Spark Plug PSI - 80000064 Spark Plug Wire 48 | P a g e...

  • Page 55: Service Procedure

    – SECTION 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Maintenance Schedule Power Solutions International, Inc. - 8.8L Gasoline Engine Service Procedure Miles (Kilometers) Hours Months Change Oil and Filter 5,000 (8,000) Perform Coolant Quality Check (including Freeze Point) Perform Annual Inspection...

  • Page 56: Coolant Level

    – SECTION 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) EXTERNAL LEAKAGE COOLANT LEVEL Service Interval: Before Engine Operation Recommended to check before engine operation. NOTE: Be sure to use a 50/50 blend of DEX-COOL WARNING: To prevent personal injury or death, shut and distilled water.

  • Page 57: Belt, Air Intake Piping And Clamps

    – SECTION 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) Inspect condition of all drive belts (Figure 18). Install a new belt if any of the following conditions exist: BELT, AIR INTAKE PIPING AND CLAMPS Excessive wear • Service Interval: Check every 15,000 miles (24,000 km), 18 •...
  • Page 58 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) Installing the Belt Air Compressor Belt BELT, AIR INTAKE PIPING AND CLAMPS (cont.) – Attach a 3/8 inch drive ratchet and a 15mm socket to the Removing the Belt tensioner.
  • Page 59 – SECTION 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) BELT, AIR INTAKE PIPING AND CLAMPS (cont.) Figure 17: Typical Main Drive Belt Routing Figure 18: Typical Air Compressor Belt Routing 53 | P a g e...

  • Page 60: Oil Level

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 1. Park vehicle on level ground. GOVERNMENT REGULATION: Engine fluid (oil, NOTE: Do not check oil level if engine is running or fuel, and coolant) may be a hazard to human health and immediately after engine shutdown.

  • Page 61: Engine Oil And Filter

    – SECTION 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) 13. Check the oil level gauge. Oil level must be within the crosshatched operating range. ENGINE OIL AND FILTER 14. Start the engine and run at low idle. 1. Park the vehicle on level ground. Set the parking brake 15.

  • Page 62: Electrical System

    – SECTION 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) ELECTRICAL SYSTEM Service Interval: Annually 1. Check wiring harness for cracks, rubbing, and loose connections. 2. Check sensors for loose connections, corrosion, or cracks. 3. Check battery cables for the following conditions: •...
  • Page 63 – SECTION 6 LONG TERM STORAGE 57 | P a g e...

  • Page 64: General Information

    SECTION 6 – LONG TERM STORAGE General Information Storing an engine over six months: If the engine or vehicle is to be placed in storage for a period of (Follow all previous procedures in addition to the following.) one to six months, it is recommended that the following steps be followed: Drain the engine crankcase and refill with recommended •...
  • Page 65 – SECTION 6 LONG TERM STORAGE • Allow engine to run at idle for approximately 5 General Information (cont.) minutes, then raise engine to a ‘high idle’, 1000- 1500 RPM and bring to full operating temperature. Removing an Engine from Storage Watch all gauges closely, if any system is out of When removing an engine or vehicle from storage, the following specification shut down engine immediately and find...

  • Page 66: Section 7 - Service Records

    SECTION 7 – SERVICE RECORDS 60 | P a g e...

  • Page 67: Maintenance Service Record

    – SECTION 7 SERVICE RECORDS Maintenance Service Record WARNING: To prevent personal injury or death, read safety instructions “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures.
  • Page 68 SECTION 7 – SERVICE RECORDS Maintenance Service Record (cont.) Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced 62 | P a g e...
  • Page 69 – SECTION 7 SERVICE RECORDS Maintenance Service Record (cont.) Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced 63 | P a g e...
  • Page 70 SECTION 7 – SERVICE RECORDS Maintenance Service Record (cont.) Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced 64 | P a g e...

  • Page 71: Daily Care And Report

    – SECTION 7 SERVICE RECORDS Daily Care and Report WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, put transmission in neutral or park, set parking brake, and block wheels before doing diagnostic or service procedures.
  • Page 72 SECTION 7 – SERVICE RECORDS Daily Care and Report (cont.) Daily Care and Report M o de l Serial No. L u b e Service Performed D a t e M i l es F u e l Parts Labor O i l Q t y C o s t...
  • Page 73 – SECTION 7 SERVICE RECORDS Daily Care and Report (cont.) Daily Care and Report M o de l Serial No. D a t e M i l es F u e l L u b e Service Performed Parts Labor O i l Q t y C o s t...

  • Page 74: Appendix

    APPENDIX 68 | P a g e...

  • Page 75: Engine Specifications

    APPENDIX Engine Specifications Power Solutions International, Inc. - 8.8L Gasoline Engine U n i t General Specifications Item Engine Type Big Block V-8 Fuel Type Gasoline Number of Cylinders Displacement 535 (8.767) Compression Ratio 9.1:1 HP (KW) 265 (198) Rated Power...
  • Page 76 APPENDIX Engine Specifications Power Solutions International, Inc. - 8.8L Gasoline Engine Cooling System Specifications (at Sea Level) Item Unit Engine Coolant Capacity 16 (14.2) qts (L) Coolant Type DEXCOOL 50/50 Standard Thermostat Range Full Open 214 (101.1) F° (C°) Closed 190 (87.2)
  • Page 77 APPENDIX Type Emissions US EPA & CARB OBD HD-SI Certification Certification Type On-Highway Heavy Duty Otto-Cycle for GVWR > 14,000 lbs. Certification Level Three Way, Ceramic Aftertreatment Type 71 | P a g e...
  • Page 78 APPENDIX Power Solutions International, Inc. 72 | P a g e...

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