Related Manuals for Marine Power 5.3 GEN V DI
Summary of Contents for Marine Power 5.3 GEN V DI
- Page 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...
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Page 2: Table Of Contents
Table of Contents 1: i ..........21-22 13: i ection ntroduction losed ooled ngines ection nStallation nStructionS 65 ..............1 ...............41 ..........23 roPosition losed nBoard ngines ngine omPartment ..............1 ..............41 afety arnings ngine ounting 10: e ection ngine aintenance ..............1 ..............41 ePlacement arts ngine otation... -
Page 3: P Roposition 65
Introduction Safety Warnings Replacement Parts Marine Power would like to thank you again for your pur- DANGER chase. The pleasure and peace of mind derived from your new DANGER Use of replacement parts (i.e. automotive, after-market, etc.) in the engine is in direct proportion to the amount of care that it is DANGER electrical, ignition and fuel systems, which are not U.S. -
Page 4: Safe Boating
California and EPA’s stringent anti-smog DAYS AFTER DATE OF PURCHASE BY FIRST OWNER. standards. Marine Power Holding LLC must warrant the emission control The waterways are becoming increasingly crowded and, in order system on your Inboard engine for the periods of time listed on the next... - Page 5 DAMAGES, WHETHER OR NOT FORESEEABLE. NO EMPLOYEE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED Marine Power Holding LLC distribution center as soon as a prob- OR REPRESENTATIVE OF MARINE POWER IS AUTHORIZED TO WARRANTIES ARE EXCLUDED. LIABILITY FOR INCIDENTAL OR lem exists.
- Page 6 Marine Power Inboard marine engine manufac- for the remainder of the period. 8. Marine Power is liable for damages to other engine compo- tured after January 1, 2008, that the emissions control devic- nents proximately caused by a failure under warranty of any 4.
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Page 7: W Arranty
A) Use of an accessories or parts not manufactured or sold by 5) Ignition Wires Marine Power. 15. Marine Power reserves the right to limit warranty coverage D) Lubrication System on engines that have accumulated excessive hours through B) Neglect, failure to follow maintenance schedules, 1) Oil Pump and Internal Parts commercial use or any other non-typical operation. -
Page 8: Carbon Monoxide Exposure
Introduction covers engine related defective material and/or workmanship 2. Damages caused by extreme temperatures in the exhaust only, and not replacement or refund of the equipment to which system, including, but not limited to any occurrences of fire, DANGER the engine may be mounted. etc.;... - Page 9 Engine Identification Every Marine Power Engine is equipped with an Engine Identifi- cation Tag, also known as a Serial Number Tag. This tag contains information (model number and serial number) that will be required before any warranty work (if necessary) can be done.
- Page 10 Engine Identification 5.3 GEN V DI 6.2 GEN V DI 6.2 LT4 Engine Type Repower Original Equipment Unique Feature Direct Injection Direct Injection DI Supercharged Displacement 5.3L/327 CID 6.2L/374 CID 6.2L/374 CID Bore & Stroke 96 x 92 mm 103.25 x 92 mm 103.25 x 92 mm...
- Page 11 Electronic Sequential Fuel Injection Information The engines covered in this manual are equipped with • Engine Coolant Temperature (ECT) Sensor Engines may include one or more of the following optional Electronic Sequential Fuel Injection. The main fuel system sensors. • Engine Oil Pressure Sensor components include: •...
- Page 12 Engine Alarms and Instrumentation Digital Alarms If the “MIL” lights and/or the “buzzer” sounds during opera- tion, the operator should scan the instrument panel readings for If, for any reason, one or more of these sensors or associated possible sources of trouble. Conditions that may cause alarm ac- wiring malfunctions, the ECM’s built in self-diagnostic system sets tivation include: a trouble code and turns on the Malfunction Indicator Light (MIL)
- Page 13 Engine Alarms and Instrumentation Instrumentation IMPORTANT: Engines are designed to use both buzzers and MIL lamps. Buzzers are Boat builders use many different types of instrumentation in their use to alert operators of severe problems, boats. The operator should understand his instrumentation and note any abnormal operating conditions.
- Page 14 SSVEC Fuse and Relay Enclosure 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. www.MarinePowerUSA.com...
- Page 15 SSVEC Fuse and Relay Enclosure www.MarinePowerUSA.com...
- Page 16 SSVEC Fuse and Relay Enclosure www.MarinePowerUSA.com...
- Page 17 SSVEC Fuse and Relay Enclosure www.MarinePowerUSA.com...
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Page 18: Hydrolock
Engine dipstick level may change due to the angle of An exhaust system without flappers and the specified incline ENGINE immediately and contact your Marine Power dealer. installation. Ensure that “high” oil level is properly marked increases the likelihood of water entering the engine. -
Page 19: Starting Engine Efi
Engine Break-In/25 Hour Inspection the fuel system. Gasoline vapors are highly explosive under certain conditions. To insure the maximum life of your Marine Power Engine, the Marine Power recommends the use of fuel stabilizer such as following engine break-in guidelines are recommended. - Page 20 DANGER Engine Operating Instructions Do not operate the boat at or near the maximum capacity WARNING specified on the USCG label. Limit the maximum engine speed to 3500 RPM The LT4 Is a Premium 93 Octane REQUIRED engine. The engine will Avoid running the engine at a constant/steady RPM for sustained operate at significantly reduced power output with octane levels periods of time.
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Page 21: Losed C Ooled E Ngines
Winterization Full Closed Cooled Engines Test antifreeze-water concentration to assure adequate protection for your location. Remove hoses from inlet and outlet of crankshaft seawater pump. Remove drain plug from transmission/engine oil cooler. Remove drain 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. -
Page 22: Losed I Nboard J Et E Ngines
Winterization LT4 Water Flow Full Closed Inboard Jet Engines Orange represents coolant flow Test antifreeze-water concentration to assure adequate protection Green represents raw water flow 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. -
Page 23: Scheduled Maintenance By Owner
Inspect Belts for Tension and Wear Inspect Battery (Terminals and Fluid Levels) Check Battery Connection to Engine Touch Up Exterior Surface with Marine Power Paint Inspect Zinc Anodes in Heat Exchanger for Deterioration (If Equipped with Closed Cooling) Check Power Steering Fluid (If Equipped) - Page 24 Engine Maintenance Scheduled Maintenance By Qualified Technician Service Engine After Every 50 Every 100 Startup 10 Hours of Hours of Hours of Each Day Operation Operation Operation Change Engine Oil and Filters Change Filter on Fuel/Water Separator Check Engine Mounts (Tightness) Check Riser and Manifold Bolts for Tightness Check for Loose, Damaged or Missing Engine Parts Check Wire Harness Plugs for Corrosion and Connections...
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Page 25: Crankcase Oil Change
Inspect entire engine for leakage. Shut CAUTION by Marine Power. A marine environment is a tough one. Parts off engine and wait 5 minutes for oil to drain back into pan. Check subjected to salt water can rapidly corrode and engine failure level with dipstick. -
Page 26: Ilters
Oil being ALWAYS CONTACT YOUR NEAREST MARINE POWER splashed by reciprocating engine parts onto the walls of the cylinder SERVICING DEALER IF YOU HAVE A PROBLEM. -
Page 27: Flame Arrestor
Engine Maintenance Not used on LT4 Flame Arrestor Fuel Flow Schematic Clean the flame arrestor regularly. High Pressure Feed Pump Low Pressure Feed Pump is 4-7 PSI at outlet. 1. Remove fastener from flame arrestor. Outlet (60 PSI) Inlet has a small screen inside fitting. This screen 2. -
Page 28: Battery Cables
DANGER DANGER Engine Maintenance Battery Cables Alternator Belt Tension WARNING WARNING Do not recharge a weak battery in a boat. Remove and recharge Make sure ignition key is removed and engine is not running before in a ventilated area away from fuel vapors, sparks or fames. inspecting belts. -
Page 29: Closed Cooling System
The closed cooling system is designed to provide extended life required. to your new Marine Power engine. Your engine will operate at Filler Neck and Pressure Cap: DO NOT remove a different temperature range from a raw water cooled engine. - Page 30 Engine Diagnostics and Codes Name Description Trouble Buzzer Reduce Comments Code Lamp Barometric Sensor Sensor alerts ECM if barometric measurement is to high or to low. Boost Bypass 66034 Boost Control ECM detects either an over boost or problem with circuit. 66035 Only applies to supercharged engines.
- Page 31 Engine Diagnostics and Codes Name Description Trouble Buzzer Reduce Comments Code Lamp Emergency Stop Warning 65710 Electronic Spark Timing Circuit (EST) ECM sets code if ignition coil fails diagnostic test. 65541-48 Last digit corresponds to coil number. Electronic Throttle Control ECM sets code if dual sensors out of range.
- Page 32 Engine Diagnostics and Codes Name Description Trouble Buzzer Reduce Comments Code Lamp Hpfp Solenoid 66029 Hpfp Solenoid Enable 66028 66051-58 Inj Enable 651-58 Inter Cooler Replay ECM detects abnormal relay current or voltage. 66030 Only applicable on supercharged engines. Driver controls intercooler pump relay.
- Page 33 Engine Diagnostics and Codes Name Description Trouble Buzzer Reduce Comments Code Lamp Oil Temperature Warning Sensor alerts ECM if engine oil temperature is above 300° F. Reduces RPM to 2500. Not used on 5.7 Engines. Oxy Fuel Trim ECM sets code after detecting abnormally rich or lean condition. 65565-66 65 indicates odd bank, 66 even bank.
- Page 34 Engine Diagnostics and Codes Start Sequence 1 (MEFI 7) “Bussmann” 2-way Connector #5 • Turn Battery Switch on (if boat equipped). A. Engine Ground 5C Energized with 12 volts B. Not used with Battery Switch on C. B+ from Starter Post (Power enters Bussmann) Connector viewed as connected to the Bussmann...
- Page 35 Engine Diagnostics and Codes “Bussmann” Connector #1 (Black) A. Auxiliary Relay B. Auxiliary Relay Control 3. ECM provides 12 volts to 1E C. Fuel Feed Pump 2 and 1F. Energizes Fuel Feed D. Powertrain Relay Pump Relays Contacts - J1-73 E.
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Page 36: Engine Will Not Turn Over
Trouble Shooting The following trouble shooting hints are not all inclusive, but are the most common found. In all cases, if the cause of the problem is outside your capability to repair or correct, contact your dealer. Engine Will Not Turn Over Possible Cause Remedy Low Battery or Bad Connection... -
Page 37: High Speed Miss
Trouble Shooting Engine Runs Poorly at High RPM Possible Cause Remedy Low Grade or Old Fuel Check/Clean/Replace Ignition Timing Only Pertains to HVS (Distributor) on 5.7L. See Dealer Active Trouble Code See Dealer Engine Overheating See Engine Overheating on Page 45 Restricted Exhaust Check Exhaust System Overfilled Crankcase... -
Page 38: Fuel System - Rich
Trouble Shooting Fuel System - Rich Possible Cause Remedy Dirty/Clogged Flame Arrester Check/Clean/Replace Malfunctioning Fuel Pressure Regulator Verify That Fuel Pressure Is Not Too High Fuel System - Lean Possible Cause Remedy Empty Fuel Tank Fill Tank Vapor Lock Ventilate Engine Compartment to Reduce Temperature Insufficient Fuel Supply Approximately 60 PSI. -
Page 39: Engine Starts And Stops
Trouble Shooting Engine Starts and Stops Possible Cause Remedy Insufficient Fuel Supply Approximately 60 PSI. Fuel Pressure Must Be Adequate at Wide Open Throttle at Full Load Loss of Ignition Power Check Ignition Switch, Main Engine Breaker, Engine Harness Connection Oil Pressure - Low Possible Cause Remedy... -
Page 40: Excessive Oil Consumption
Trouble Shooting Excessive Oil Consumption Possible Cause Remedy External Leak Clean/Check/Repair Excessive Oil in Crankcase Remove Excess Oil. Refer to Engine Identification on Page 15 for Correct Oil Level Oil/Fuel Dilution Change Oil Extended Excessive RPM’s Reduce RPM’s Incorrect Oil Viscosity Change to Proper Oil Engine Vents Blocked Unblock Vents... - Page 41 Trouble Shooting Water in Engine Cylinder or Base Possible Cause Remedy Operator Error See Section 7: Precautions on Page 23. REMOVE Water from Engine Immediately Exhaust Restricted or Blocked Repair or Replace. REMOVE Water from Engine Immediately Engine and Exhaust Too Low in Boat Reroute Exhaust Hoses or Add Riser Spacers.
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Page 42: Ngine C Ompartment
Installation Instructions NOTE: Before shipment, each engine has been carefully tested • Front of boat is bow (50% antifreeze + 50% water) and seawater for cooling. The and inspected. It may be necessary to delete or add oil from closed cooling system will operate at 170° - 190° F. The system •... -
Page 43: Xhaust Iping
Damage caused by water in the Trailerable Boat 0.40 25.6 – 32.2 SPORTPACS AND TOWPACS use thru-hull fittings to supply engine will not be covered by the Marine Power warranty, Non-trailerable Boat 0.16 27.6 – 30.2 cooling water to the sea water pump. -
Page 44: Electrical Connection
A minimum of 18” of exhaust hose must be installed between the Battery Isolators NOTE: Marine Power EFI engines are equipped with “Smart exhaust risers and the collector, Y-pipe, muffler or first angular Start” this feature is common in late model automobiles but is Many boats are equipped with auxiliary batteries. - Page 45 Installation Instructions Battery Cable Length Requirements the fuel tank pick up tube should be no more than 30”. The fuel Hoses and Fittings: Use only USCG Approved fuel lines. Make pump must also be placed as low to the bottom of the fuel tank sure that the fuel line routing is not touching any sharp edges.
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Page 46: N Otes
Installation Instructions Airboat Installation Notes: All GEN V DI engines require modified belt drive housings. Century Drive is aware of the required modifications. Engines require engine oil coolers. LT4 engines require radiators for DANGER intercooler heat rejection. Intercooler radiator should be large enough to maintain Manifold Air Temperature at WOT. -
Page 47: A Dapter H Arness
Installation Instructions Adapter Harness for Analog Instrumentation Harness M6 - 21 Pin to 10 Pin #473063 www.MarinePowerUSA.com... - Page 48 Installation Instructions Adapter Harness for Digital Gauges Harness M6/M7 #472908 www.MarinePowerUSA.com...
- Page 49 Installation Instructions Adapter Harness for Digital Faria Panel Harness MEFI 6/7 #472922 www.MarinePowerUSA.com...
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Page 50: Heater Connections
Installation Instructions Heater Connections LT4 Engine 4.3/6.2 DI From Heater To Heater www.MarinePowerUSA.com... -
Page 51: Prestart Checklist
Prestart Checklist 7. On inboard, V-drive and stern drive applications verify that 10. Check that all engine mounts are tight the engine will not start unless the shifter is in the neutral 11. Check that the battery is secure, and that all electrical 1. - Page 52 Installation Instructions Potentiometer Operation The throttle lever rotates assproximately 80°. Maximum clockwise (CW) rotation is idle. Maximum counter-clockwise (CCW) rotation is wide open throttle (WOT). The Potentiometer has contacting wiper blades which produce 2 output voltages (PPS1 and PPS2). Both PPS1 and PPS2 output voltages should be adjusted to .78 volts at idle and 4.1 volts at WOT.
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Page 53: T Ransfer
Please enclose check or money order in the amount of $300.00 per engine to be transferred. You may pay by credit card. Complete the information below. VISA MASTERCARD Card Number: _____________________________________________________________________ Exp. Date: ______________________________________ Name As It Appears On the Credit Card: _________________________________________________________________________________________________ Signature: _______________________________________________________________________________________________________________________ Mail completed form to: Warranty Registration Transfer, Marine Power, 17506 Marine Power Industrial Park, Ponchatoula, LA 70454 www.MarinePowerUSA.com... -
Page 54: Ervice Og
Service 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 www.MarinePowerUSA.com... - Page 55 Service Log Date Service/Maintenance Performed Performed By Operating Hours www.MarinePowerUSA.com...
- Page 56 All rights reserved. No part of this book may be reproduced or utilized 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.