Table of Contents
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I L M O R M A R I N E
I L M O R M A R I N E
Please read this Owner's Manual completely prior to operating the engine and boat for the first time. The Owner's
Manual contains information critical for safe operation, and to activate and keep the limited warranty statement in ef-
fect throughout the applicable warranty period. Continuing the appropriate maintenance and care going forward can
ensure long-term enjoyment of the MV8 engine. DO NOT OPERATE THE ENGINE WITHOUT FIRST READING THE ENTIRE
MV8 OWNER'S MANUAL AND ALL SUPPORTING DOCUMENTATION, AS WELL AS THE BOAT OWNER'S MANUAL.
ILMOR Marine, LLC, is pleased to welcome you to boating
enjoyment available only through use of the extraordinary MV8
engine. ILMOR is a recognized leader in the marine industry, hav-
ing originated through championship-caliber, high-performance
engines. Our experience inevitably led to the development of the
MV8, offering 5.7, 6.0 and 6.2 liter versions, which provide the
appropriate power range for ideal wakeboarding at 18 miles per
hour, and with equal execution when skiing at 30 mph. We didn't leave out the simple joy of skimming across the surface from
10 mph to 45 mph with the same level of quality performance. The MV8 provides the kind of horsepower necessary to plane
with pulse-pounding quickness while equally ensuring the reliability and smoothness necessary for just-above-idle investigation
of interesting coves and shorelines. It's all here.
The MV8's heritage extends back to the company's founding in 1983, when Swiss-born Mario Illien and British native Paul
Morgan sent a handwritten letter to American businessman and team owner Roger Penske. The duo proposed a new company
that would design and build turbocharged engines for race cars. Penske was intrigued and within three months ILMOR Engi-
neering was born.
Working with various international companies over the years, ILMOR has enjoyed unparalleled success in many forms of
racing, particularly Formula 1 and Indy Car racing. In fact, partnered with Honda, ILMOR is currently the sole provider of
engines to the Indy Car circuit.
substantial growth, becoming a well-established sup-
plier in the U.S. and European high-performance boat
market. In addition to the MV-550 V-10 engine, ILMOR
has added two more packages: the MV-625 in 2005, and
the MV-710 in 2006. The 700-horsepower, naturally-as-
pirated marine engine was developed with significantly
improved fuel efficiency and a light-weight package, fac-
tors that would add to the superiority of the MV8 in its
development stage.
In 2009, ILMOR had to utilize its substantial engineer-
ing expertise to create an entirely new generation of MV-
10 marine products. Emissions requirements established
by the California EPA (the most stringent in the U.S.)
and the federal Environmental Protection Agency meant
that all high-performance marine engines had to meet
tough new exhaust emissions standards. The MV-650 and
the MV-725, along with state-of-the-art ILMOR elec-
2011 ILMOR MV8 Owner's Manual • Page i
WELCOME
Since 2004, ILMOR's marine division has enjoyed
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Table of Contents
Related Manuals for ILMOR 2011 MV8
Summary of Contents for ILMOR 2011 MV8
- Page 1 Working with various international companies over the years, ILMOR has enjoyed unparalleled success in many forms of racing, particularly Formula 1 and Indy Car racing. In fact, partnered with Honda, ILMOR is currently the sole provider of engines to the Indy Car circuit.
- Page 2 Everyone knows that creating horsepower is easy. Creating horsepower output in the correct range for the correct application, however, is a challenge to which ILMOR was more than equal. You are about to benefit from this knowledge and experience.
- Page 3 Personal flotation devices (“PFDs”) save lives and ensure positive experiences. ILMOR offers many proactive approaches to the boating expe- rience, but the consumer is ultimately responsible for the positive and safe involvement in boating.
- Page 4 ENGINE! Remove the key from the ignition switch and call an authorized boat and/or ILMOR dealer for service. Take care not to spill gasoline when fueling. If gas is spilled accidentally, wipe up all traces with dry rags immediately and dispose of properly on- shore.
- Page 5 This could result in serious injury or death. (Page 19) Any time the engine is running, an adequate amount of water as defined by ILMOR Marine MUST be flowing through the cooling system. This requires the boat to be in an operational-sized body of water or hooked up to the suction side of a raw water pump via an ILMOR-approved, water supply in a dealership.
- Page 6 Extended storage with fuel in the system can affect fuel stability and may require system inspection and fuel filter replacement when the boat returns to service. (Page 12) Damage to the engine by use of low-quality or non-specified oil as listed for ILMOR MV8 engines will void the warranty on the engine. (Page 13) Damage to the engine by use of low-quality or non-specified transmission fluid/oil as listed for V-Drive and direct drive transmissions will void the warranty.
- Page 7 (25) hours. At that time, an oil change should be performed by an authorized ILMOR dealer, who will be able to “read” the oil and filter to determine if the proper break-in of the engine components appears to be occurring.
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Page 8: Table Of Contents
Clean Any Residue ................22 Starting, Stopping and New Engine Break-In ........23 First Hours of Operation ..............24 After Initial Hours of Operation ..............24 Before the Engine Is Started ..............24 Starting the Engine ................25 2011 ILMOR MV8 Owner’s Manual • Page viii... - Page 9 Emissions Control System Warranty Parts ..........45 Troubleshooting.................47 ILMOR Marine LLC Limited Product Warranty ........48 Specifications and Service Log .............53 Engine Specs ..................53 Requirements & Recommendations ............53 Maintenance Requirements..............54 Service Log ..................55 Index ....................56 2011 ILMOR MV8 Owner’s Manual • Page ix...
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Page 10: Safety
ILMOR. Every reasonable effort has been made to provide directions to safe and thoughtful use of the ILMOR product. In most instances, adherence to common sense when operating or working around the engine will present the boat op-... -
Page 11: Direct Safety Concerns
ILMOR dealer or authorized boat manufacturer dealer if at all possible. If adjustments are necessary while the boat is underway or in preparation for boating, extreme care should be used. -
Page 12: Of Introducing The Mv8
I N T R O D U C I N G T H E M V 8 I N T R O D U C I N G T H E M V 8 2011 ILMOR MV8 Owner’s Manual • Page 3... - Page 13 Use photos or drawings as necessary to designate important components, including interal; allow two pages for THERMOSTAT LOCATION these. CRANKSHAFT DAMPER EXHAUST MANIFOLD DRAIN PLUG ENGINE CONTROL MODULE ENGINE OIL FILTER LOCATION ENGINE O2 SENSOR 2011 ILMOR MV8 Owner’s Manual • Page 4...
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Page 14: Exhaust System
The exhaust manifolds are water-cooled. Water temperatures in the exhaust manifolds range from 158 F. to 194 F. (70 C. to 90 C.) The ILMOR exhaust mani- fold water temperatures are approximately 50-66 per cent warmer than exhaust manifolds on engines without catalytic converters. -
Page 15: Cooling System
In the event that the fuel system supplying the MV8 engine requires attention, any ad- justment or replacement must be done by an authorized ILMOR dealer as the lines are pressurized and can be disconnected only with specialized tools. Replacement of any part of the fuel system must be with ILMOR-authorized parts only. -
Page 16: Open Cooling System
The engine recirculation pump re- circulates coolant through the engine and exhaust manifolds. Raw water never enters the engine or exhaust manifolds. 2011 ILMOR MV8 Owner’s Manual • Page 7... -
Page 17: Electrical System
The fuse box is mounted on the rear of each MV8 engine. 2011 ILMOR MV8 Owner’s Manual • Page 8... -
Page 18: Boat/Engine Interfacing Wiring
Because nearly all sensors are located inside sealed areas of the engine, and diagnostics are normally done utilizing highly techni- cal and expensive tools, consumers are urged to take the boat to an authorized ILMOR dealerships for analysis if or when a malfunction is suspected. -
Page 19: Oil Temperature
If the sea water pressure is normal (less than 5 psi at idle) the coolant temperature should begin to return to normal. If the temperature continues to increase, shut down the overheated engine immediately and take the boat to an authorized ILMOR dealer. The alarm appears... -
Page 20: Fueling The Mv8
THE ENGINE! Remove the key from the ignition switch and call an authorized boat and/or ILMOR dealer for service. Take care not to spill gasoline when fueling. If gas is spilled accidentally, wipe up all traces with dry rags immediately and dispose of properly on-shore. -
Page 21: Oxygenated Gasoline Or Gasoline Containing Alcohol
TIER specifications. For a list of TOP TIER retailers, check www.toptiergas.com, and click on “Retailers.” Damage to the engine by use of low-quality gasoline or gasoline with an octane rating below the minimum level listed for ILMOR MV8 engines will void the warranty on the engine. E-85 fuels... -
Page 22: Other Pre-Outing Requirements
50 hours thereafter. Oil should also be changed if the temperature for any reason has ex- ceeded 329 F. (165 C.) Always change the oil filter every time the oil is changed, using only ILMOR-approved filters as listed in the Maintenance section of this Owner’s Manual. Operators should also verify the oil level prior to every operation, as indicated in the Prior to Each Use section of this Owner’s Manual. Damage to the engine by use of low-quality or non-specified oil as listed for ILMOR MV8 engines will void the warranty on the engine. The oil capacity for all three MV8 engines is five (5) quarts during oil change. The V-drive and direct drive transmissions requires lubrication to function properly. Your dealer can verify the type of transmis-... -
Page 23: Before Each Use
Any resulting damage will not be covered by the warranty. • Inspect the inside of the impeller housing. If any rubber extrusions on the end of the arm appear frayed or worn, it should be replaced. Debris enter- ing the impeller inevitably will damage it. However, the impeller serves its purpose in deflecting debris and keeping it out of much more expensive internal engine parts. • Any uncertainty about the condition of the impeller means that it should be removed and inspected. The impeller fits very snugly and will require some care in removing and re-installing or installing a new one. This en- sures proper operation. T he use of soap or water-based petroleum jelly will help with installation. Note that proper placement on the gear results in a squeeze on the arms. This is the correct installation. • Place a gasket between the housing and the cover after ensuring that the surfaces are smooth and clean. Re-install the screws loosened when the face plate was removed earlier. Do not over-tighten the brass screws as it will cause them to break. 2011 ILMOR MV8 Owner’s Manual • Page 14... -
Page 24: Check The Transmission Cooler
(in order to avoid burns), it is recommended that this Coolant Level check be completed prior to starting the engine. • Ensure the engine is OFF and the engine safety starting switch is disconnected. Leave the throttle/shift control lever in neutral. Open the engine compartment. Locate the closed cooling system tank adjacent to the engine. • Remove the cap and check the level. V erify that the fluid is at the FILL line. (When the engine heats, the water will expand; that is the reason the tank should not be full when the engine is cold.) If the level is at or below that, add ILMOR antifreeze. Use premixed 50/50 or use a 50/50 mix of ILMOR antifreeze and distilled water. T he cooling system will take between 5.8 gallons (22L) and 6.8 gallons (26L) of coolant in total. 2011 ILMOR MV8 Owner’s Manual • Page 15... -
Page 25: Check The Alternator Belt For Looseness Or Damage
Because this process should be completed while the engine is cool (in order to avoid burns), it is Battery Connections recommended that this check be completed prior to starting the engine. and Hold-Downs • Ensure the engine is OFF and the engine safety starting switch is disconnected. Leave the throttle/shift control lever in neutral. Locate the battery(ies). Bat- teries are placed in a variety of locations, depending upon the model. Refer to the boat manufacturer’s Owner’s Manual for details. In most instances, the battery(ies) will be under the observer’s seat or behind one of the rear seats. • Check that the battery post connections are clean and tight. If not, loosen and remove the negative terminal connection first. Be careful to avoid touching the positive terminal with the wrench or negative connection. Then loosen and remove the positive terminal connection. Remove the battery hold-downs 2011 ILMOR MV8 Owner’s Manual • Page 16... -
Page 26: Inspect The Engine For Loose Or Missing Hardware
If other electrical components or accessories are added, it may change the way the fuel injection controls the engine or the overall electrical system func- tionality. Before adding electrical equipment, consult an authorized ILMOR dealer. If you do not, your engine may not perform properly. -
Page 27: Inspect The Fuel And Exhaust Systems For Leaks
As the boat is started, check all gauges but pay particular attention to the voltmeter. Check that the Battery Is Fully Charged When starting the engine, check that the voltmeter reads between 12.8 and 14 volts on the voltmeter. An erratic reading can be a sign of low voltage. T he voltmeter is the best indication of the state of the battery. However, it is not fool-proof. While the reading will indicate that the battery is producing current, if in a previous outing there was reason to suspect a problem with the battery(ies), check with an authorized ILMOR dealer. Many boat models are equipped with a low-voltage battery alarm. This system may also turn off accessories when the voltmeter falls to a certain pre-set level. T he objective 2011 ILMOR MV8 Owner’s Manual • Page 18... -
Page 28: Check The Transmission Fluid/Oil Level
Different transmissions will have their own type of dipstick. The The two types used on V-drive and direct drive transmissions used in conjunction with the MV8 engine will have either a threaded or non-threaded dipstick. Those without threads expand when the handle is turned in a clockwise direction after the dipstick is inserted. • If the dipstick and the transmission housing void are not threaded, ensure that the dipstick is fully inserted in the void prior to use. T his is required for the expansion and correct operation. The dipstick has a T handle. • If the dipstick and housing void are threaded, there will be an o-ring between the dip- stick and housing void to provide the necessary seal. The handle has a fuller grip area than the T-handled, non-threaded dipstick. • Remove the dipstick and wipe it off with a clean rag. Quickly re-insert it fully, and then immediately remove it. Check that the level is between the ADD and FULL mark on the stick. 2011 ILMOR MV8 Owner’s Manual • Page 19... -
Page 29: Check The Engine Oil Level
Add oil if necessary through the oil fill neck and only enough to bring oil within the two marks. Overfill may result in damage to the engine that may not be covered by the warranty. Use oil as specified in the Oil Requirements section of the Introducing the MV8 Engine chapter or the Service Log in this Owner’s Manual. DO NOT USE OIL ADDITIVES AT ANY TIME. 2011 ILMOR MV8 Owner’s Manual • Page 20... -
Page 30: After Each Use
T he engine needs to be at its operating temperature for fifteen (15) minutes. T he garden hose flow rate may need to be adjusted if engine will 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 thermostat and flush engine with fresh water for five (5) minutes while cycling the engine speed from idle to 2000 rpm in 10-second intervals. • Fresh water boats should be flushed when going to storage or not being used for periods in excess of one month. • Salt water boats should be flushed with fresh water after every use. Boat- in-water flushing can be achieved with a flushing device. The seacock will need to be closed while supplying fresh water to the inlet of the sea pump and allowing it to circu- late through the engine. T he engine must reach operating temperature for a minimum of five (5) minutes to allow the thermostat to open and circulate fresh water. 2011 ILMOR MV8 Owner’s Manual • Page 21... -
Page 31: Check For Leaks
Since gaseous and/or fluid leaks are more likely to be apparent at the conclusion of an Check for Leaks outing, the operator should open the engine compartment and check for any odor or dis- coloring of components. Any sign of leakage should be brought to the attention of an authorized ILMOR dealer immediately! Clean Any Residue Normal operations will still result in a small amount of ambient fluids. If a small amount of oil or other innocuous fluids are found on the engine, transmission or within the engine compartment, wipe down the residue with a clean rag. Keeping the engine compartment pristine helps to determine if an engine develops a more significant issue later on. 2011 ILMOR MV8 Owner’s Manual • Page 22... -
Page 32: Starting, Stopping And New Engine Break-In
(10) hours proper operation, but not later than twenty-five (25) hours. At that time, an oil change should be performed by an authorized ILMOR dealer, who will be able to “read” the oil and filter to determine if the proper break-in of the engine components appears to be occurring. -
Page 33: First Hours Of Operation
HOURS OF Move the throttle/shift control lever forward, smoothly and quickly, to planing speed. Then return the throttle back to a slower speed, but one that continues the plane. Vary the OPERATION engine speed but do not exceed 3,000 rpm for the first hour, and carry only a light load. After the first hour, the rpm may not exceed 5,200 rpm for the 5.7L or 5,400 rpm for the 6.0L and 6.2L engines. Reduce the throttle/shift control lever to idle (neutral) occasionally for a cool-down period. The boat MUST be returned to the authorized ILMOR dealer for a mandatory oil change between ten (10) and twenty-five (25) hours of operation. This ensures the service staff will be able to determine whether any internal issues may be apparent. After the break-in and oil change AFTER have been completed, the engine may be operated more continuously at speed, but never beyond the maximum, and it is al- INITIAL ways advisable to give the engine an occasional cool-down period. For the 5.7L engine, the maximum is 5,200 rpm; for the 6.0L, the maximum is 5,400 rpm; and for the 6.2L, the HOURS OF maximum is 5,400 rpm. -
Page 34: Starting The Engine
The boat is likely to be equipped with sea strainer valves and seacocks. Ensure these are open prior to starting the engine. Any time the engine is running, an adequate amount of water as defined by ILMOR Marine MUST be flowing through the cooling system. This requires the boat to be in an operational-sized body of water or hooked up to the suction side of a raw water pump via an ILMOR-approved, water supply in a dealership. -
Page 35: Shifting Gears
This is not a land vehicle. STOPPING There are no brakes to be applied. T o stop a boat requires advance planning and operations that must be completed before reaching the dock THE BOAT or bank. • Bring the throttle/shift control lever to neutral. • If the boat has been operated for an extended period of time, or at high RPM, allow the engine a cool-down period at low idle (660 to 800 RPM) for several minutes. • Turn the key to the OFF position to stop the engine and drive train. • Coast into the dock or bank, following instructions provided by the boat manufacturer’s Owner’s Manual to properly stop the boat without damaging the hull. 2011 ILMOR MV8 Owner’s Manual • Page 26... -
Page 36: Other Considerations
Never operate the boat at continuous wide-open-throttle. This places OTHER undue strain on the engine components. Wide-open-throttle exists to allow boaters to get out of dangerous encounters or situations, but it represents the upper limit of the engine’s CONSIDER- capacity. See also the boat manufacturer’s Owner’s Manual for operational hints and tips that can ATIONS enhance the enjoyment of the boat’s and drive train’s integration. 2011 ILMOR MV8 Owner’s Manual • Page 27... -
Page 37: Maintenance
Shaft alignment Check Heat exchanger(s) Inspect/ Clean Zinc anodes Inspect #whichever comes first. * If the engine is subject to heavy use, it is recommended to change oil and filter every 25 hours. ** Services best accomplished by an authorized ILMOR dealer. ***Replace sooner if regular checks indicate water or damage. ILMOR recommends that the maintenance requirements be performed by an autho- rized ILMOR dealer. Service technicians there have the proper equipment, training and resources to best meet your service needs. In order to thoroughly drain Change the Engine Oil all the old oil, the boat engine needs to reach at least 140 F. (60 C.), which is approximately fifteen (15) minutes idle. DO NOT run the and Filter engine without it being in water. If you cannot place the boat in a body of water or do not have access to a professional off-shore hook-up (as some dealerships do) to protect the engine and drive-train components, have an authorized ILMOR dealer perform this service. If you are go- ing to warm up the engine while on a body of water, remove it from the water and immediately perform the service, ensuring the proper draining and disposal/recycling of the old oil. 2011 ILMOR MV8 Owner’s Manual • Page 28... - Page 38 ILMOR blended synthetic is the recommended oil for use in the MV8 engine. Use of supplemental oil additives is not required. ILMOR blended synthetic contains all the necessary additives for the MV8. • Ensure the engine is OFF and the engine safety starting switch is disconnected. Leave the throttle/shift control lever in neutral. The engine must be warm. • Open the engine compartment and locate the oil drain hose, which runs from the bottom of the oil pan along the port side of the engine. At the end of the oil drain hose is a brass plug. Note: Never drain oil into the bilge or into the water. Wipe up any spilled oil immediately and dispose of the rags and drained oil in a proper manner on- shore.
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Page 39: Change The Transmission Fluid/Oil & Filter
(as some dealerships do) to protect the engine and drive-train components, have an authorized ILMOR dealer perform this service. If you are going to warm up the engine while on a body of water, remove it from the water and immediately perform the service, ensuring the proper draining and disposal/recycling of the old fluid/oil. -
Page 40: Clean The Engine Flame Arrestor/Air Filter
Note: DO NOT use gasoline, steam, caustic cleaning solution, strong detergent, high- pressure car wash or parts cleaning solvents. Any of these can harm the cotton filter media, as well as shrink and harden the rubber and caps. • Either spray on ILMOR air filter cleaner or allow the air filter to soak in a pan filled with air filter cleaner. Allow the cleaner to work for approximately ten (10) minutes. 2011 ILMOR MV8 Owner’s Manual • Page 31... -
Page 41: Replacing The Raw Water Impeller/Sea Pump Impeller
Note: Never use the air filter without oil. The filter will not stop the dirt without the oil. Red dye is added to ILMOR air filter oil to assist in determining whether you have complete coverage after application. Never use automatic transmission fluid, WD-40, LPS, other lightweight oils or anything not specified for this purpose. -
Page 42: Raw Water (Sea Water) Draining And Filling
For open cooling systems: • Drain exhaust manifolds of raw water by removing ½” NPT pipe plugs from water rails. • Drain engine block of raw water. • For 5.7L applications: Remove knock sensors/drain plugs from both sides of the engine block. • For 6.0L applications: Remove the electric heater 17mm Allen plug from engine block raw water pump side. Remove the 10mm Allen plug on starter side of en- gine block. • For 6.2L applications: Remove electric heater 17mm Allen plug from engine block raw water pump side. Remove the 10mm Allen plug on starter side of engine block. 2011 ILMOR MV8 Owner’s Manual • Page 33... -
Page 43: Coolant Draining (Changing Coolant) And Filling
(Changing Coolant) ant to drain. and Filling • Drain both exhaust manifolds by removing the end plugs on the bottom rail. • Drain the cylinder block: • 5.7L: Remove knock sensors on both sides of block. • 6.0L: Remove the electric heater 17mm Allen plug from the engine block raw water pump side. Remove the 10mm Allen plug on starter side of engine block. • 6.2L: Remove the electric heater 17mm Allen plug from the engine block raw water pump side. Remove the 10mm Allen plug on the starter side of engine block. • Re-assemble all hoses and drain plugs once all coolant has drained. • Refill cooling system with ILMOR antifreeze. Use premixed 50/50 or use a 50/50 mix of ILMOR antifreeze and distilled water. The cooling system will take between 5.8 gallons (22 L) to 6.8 gallons (26L) of coolant. • With the coolant cap off, cycle the engine speed from idle to 2000 rpm in 10-second intervals while engine temperature is below 104 F (40C). Refill the coolant reservoir as needed. • Install coolant cap. • Cycle engine speed from idle to 3000rpm in 30second intervals until the coolant tem- perature reaches 76C (169F). • Shut off the engine. • Top off coolant reservoir as needed. • Cycle engine speed from idle to 3000 rpm in 30-second intervals until the coolant 2011 ILMOR MV8 Owner’s Manual • Page 34... -
Page 44: Flush Coolers
• The serpentine belt is located on the front of the engine, except in V -drive boats where it will be at the back due to the manner in which the engine is mounted in the boat. • Using a 15mm socket wrench, remove tension from the belt by moving the ten- sioner to its maximum travel position. • Remove the serpentine belt by unwrapping it from each of the pulleys. • Check the wear on the inside grooves. If this is part of the annual maintenance, most likely the serpentine belt will need to be replaced. • To install a new belt or to reinstall the existing belt, wrap the belt around the pulleys as shown, and use a 15mm socket to rotate the tensioner to its maximum travel. T his should allow enough slack to slide the belt over the smooth, water pump pulley. • Ease the tensioner back into place and ensure that the belt is properly wrapped around all of the pulleys. • Check that the belt has the proper give. Locate the engine coolant heat exchanger. It is installed 2011 ILMOR MV8 Owner’s Manual • Page 35... -
Page 45: Replacing The Zinc Anodes (Saltwater Applications)
A protective marine oil may be applied to expo- sure metal to halt the acceleration of corrosion. Failure to pay attention to corrosion matters will void the warranty. A complete engine tune-up needs to be done at least every 300 hours or annually, whichever comes first. This includes but is not limited to: replacement of the Engine Tune-Up spark plugs and spark plug wires (if needed), a check of the installed distributor position and shaft alignment, as well as cleaning the breather hose. ILMOR strongly recommends having the engine tune-up performed by an authorized ILMOR dealer. 2011 ILMOR MV8 Owner’s Manual • Page 36... -
Page 46: Storage And Winterization
Damage due to improper storage and/or winterization preparations is not cov- ered under warranty. Owners are encouraged to seek assistance from an authorized ILMOR dealer to properly prepare the drive train for periods of inactivity exceeding two (2) weeks. Fuel System This preparation needs to be done prior to removing water from the engine, if that will be part of the process. -
Page 47: Oil Storage/Winterization
Even quality gasoline that has been properly prepared for storage should never be stored for a period to exceed one (1) year. Fuel systems on all boats equipped with ILMOR MV-8 engines MUST be properly prepared for storage periods exceeding two (2) weeks, as outlined in this Owner’s Manual. -
Page 48: Method 1-Engine Off
Approximately six (6) gal- lons of Marine/RV Antifreeze will be needed for open cooled systems. Approximately three (3) gallons will be needed for closed cooled systems. There are two methods for filling your engine with antifreeze; • Open Cooled System Method 1 • Close thru-hull water pick up sea cock. Engine Off • Fill engine block and heads from thermostat housing. Remove both exhaust header feed hoses. Lift either the port or starboard hose as high as possible and fill until full. The other removed hose allows air to purge. • Fill port and starboard exhaust manifolds by removing thermostat hose ends. Lift hose end as high as possible and fill until full. • Fill sea strainer if not full. • Closed Cooled System • Close thru-hull water pick up sea cock. • Fill raw water components by removing both one-inch (1” ) hoses from exhaust downturn adapters. Lift either the port or starboard hose as high as possible and fill until full. This should fill the raw water side of the engine heat exchanger, oil/transmission heat exchanger, raw water pump, and sea strainer. The sea strainer may need to be opened to purge air. • Fill sea strainer if not full by end of procedure. • Fill down turn exhaust adapters with 1/4 to 1/2 gallons of antifreeze. • Reinstall hoses. 2011 ILMOR MV8 Owner’s Manual • Page 39... -
Page 49: Method 2-Engine On
Engine Fogging Oil internal engine components from corrosion during long periods of in-operation. Marine engine foggers come in aerosol cans labeled “engine fogging oil.” It is recommended to use STA-BIL Engine Fogging Oil. ® 1. Remove the engine air filter. 2. Start engine and allow idling. 3. Spray fogging oil into throttle body until engine begins to choke and then immediately shut engine off. Do not allow engine to stall as this will leave the spark plugs fouled and make it difficult for restarting after storage. If the engine stalls, restart and re-do the procedure. Some engine throttle may be required to get adequate engine fogging oil in. 4. Reinstall engine air filter. Disconnect the battery(ies) and fully charge. It is recommended to take Battery the battery out of the boat and store it inside. If the battery loses charge it has the risk of Winterization being damaged due to freezing. Check the battery manufacturer’s requirements. Some may indicate that the battery should not be stored on a concrete surface. Check to make sure battery is charged every 30-45 days. Slow charge using a trickle charger if necessary. 2011 ILMOR MV8 Owner’s Manual • Page 40... -
Page 50: Recommissioning After Storage/Winterization
Recommissioning After of storage and/or winterization is equally important. Equal attention must be paid to the Storage/Winterization same components during recommissioning as during the winterization process. 1. Remove raw water pump impeller and check it carefully. If it appears to have weath- ered or there are any doubts about its ability to function properly, replace it. See the instructions for correctly installing a raw water impeller in the Maintenance section of this Owner’s Manual. T he raw water impeller should be replaced once a year or at any time during routine maintenance that it shows wear. 2. Check all fluids; oil, transmission, cooling. 3. Reinstall battery(ies) and check the battery voltage. It should be 12V –14volts. If it is less, charge the battery(ies). 4. Visually inspect the fuel system. If there appears to have been undue weathering or any leaks have appeared over the storage/winterization period, contact your authorized ILMOR dealer for correction. DO NOT start the engine if there is any appearance of leakage or rupture of any component of the fuel system. 5. Install boat hull drain plugs. 6. Marine/RV Antifreeze should be drained and recycled. It is best accomplished by run- ning the boat on the garden hose and collecting the antifreeze into buckets as it comes out of the exhaust. 7. Review the boat manufacturer’s storage and winterization recommissioning directions to ensure that all requirements have been met, prior to launching the boat. 2011 ILMOR MV8 Owner’s Manual • Page 41... -
Page 51: Emissions
EMISSIONS The emission control system information for all engines having the CONTROL Emission Control Information Label are as follows: three way catalytic converter (TWC), heated oxygen sensors (HO2S), sequential multiport fuel injection (SFI), naturally aspi- SYSTEM IN- rated (NAT), On-Board Diagnostics Marine (OBD), low-permeation fuel line (HOSE), and electronic engine control (EC). FORMATION Beginning January 1, 2009, a Four Star label is placed on the hull by MasterCraft for each certified ILMOR Marine, LLC, engine. For any boat sold or regis- STAR LABEL tered in California, the Four Star label must be affixed to the port side of the hull either forward or aft of the vessel registration as shown in the illustration below. An ILMOR MV8 engine has a Four Star – Super Ultra Low Emission rating. This in- dicates that the engines have ninety percent (90%) lower emissions than One Star – Low Emissions engines. The Four Star label identifies these engines as meeting the California Air Resources Board’s sterndrive/inboard marine engine exhaust emission standards. T his label is also located on the port side of the intake manifold. 2011 ILMOR MV8 Owner’s Manual • Page 42... -
Page 52: Hang Tag
DTCs that have been stored. This information about system malfunction assists the ser- vice technician in quickly diagnosing system issues. When the MIL lights, the owner/ operator should contact an authorized ILMOR deal to arrange a diagnostic scan at the earliest possible opportunity. DTCs are stored in the engine control unit memory and can be retrieved with an ILMOR Marine version scan tool or through Diacom PC Software. That is why it is necessary to seek assistance from the appropriate dealer. The Diagnostic Scan T ool will be connected to the Data Link Connector (DLC); a flat 6-pin connector. T he connector is located on the port forward section of the intake mani- fold and is usually marked with either DLC or Data Link Connector just behind the plug. Note that the protective DLC cover must be removed prior to connecting the Scan Tool. -
Page 53: California And U.s. Epa Emissions Control Warranty Statement
If you have any questions regarding your warranty rights and responsibilities, you should contact ILMOR Marine, LLC at 1-704-360-1900. General Emissions GENERAL EMISSIONS WARRANTY COVERAGE ILMOR Marine, LLC must warrant that the engine is: Warranty Coverage (1) Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code, and by the U.S. Environmental Protection Agency pursuant to 40 CFR 1045; and (2) Free from defects in materials and workmanship that cause the failure of a war- ranted part to be identical in all material respects to that part as described in the engine manufacturer’s application for certification. 2011 ILMOR MV8 Owner’s Manual • Page 44... -
Page 54: Emissions Control System Warranty Parts
Evaporative Low-permeation hose(s)** Miscellaneous Items Hoses Clamps Fittings Tubing Sealing gaskets or devices Mounting hardware Pulleys Belts* * Covered up to but not including the first required replacement only. See the Maintenance Schedule in the Owner’s Manual. ** MV8 5.7L only 2011 ILMOR MV8 Owner’s Manual • Page 45... -
Page 55: Parts Description
Electronic Emission-Related Control Parts Warranty: Systems Covered by this Warranty: Parts Description: Fuel Metering Fuel injectors Air/fuel ratio feedback and control system Cold start enrichment system Ignition Electronic ignition system Spark advance/retard system Miscellaneous Items Camshaft position sensor Crankshaft position sensor Engine coolant temperature sensor Intake air temperature sensor Knock sensors Manifold absolute pressure sensor Throttle position sensors Electronic Control Unit Electronic Throttle Control Camshaft position (CMP) actuator solenoid valve*** Oil Pressure Sensor*** *** MV8 6.0L only 2011 ILMOR MV8 Owner’s Manual • Page 46... -
Page 56: Troubleshooting
Vacuum leak. See authorized ILMOR dealer. Poor boat performance. Fouled spark plugs. Have dealer replace the spark plugs. Contaminated fuel. Drain fuel properly and have dealer replace the filter. Plugged flame arrestor. Clean the flame arrestor. Weak ignition coil. Have dealer replace the ignition coil. Fuel filter clogged. Have dealer replace the fuel filter. Ignition problems. See authorized ILMOR dealer. Poor gas mileage. Fouled spark plugs. Have dealer replace the spark plugs. Plugged flame arrestor. Clean the flame arrestor. Inefficient driving habits. Plane the boat quickly, then slow down to desired speed. Plugged PCV valve. Have dealer replace the PCV valve. Ignition problems. See authorized ILMOR dealer. 2011 ILMOR MV8 Owner’s Manual • Page 47... -
Page 57: Ilmor Marine Llc Limited Product Warranty
ILMOR Marine recommended main- tenance requirements or procedures or which are subject to misuse, neg- ligence, accident or neglect, or unrea- sonable exposure to the environment, so as to affect adversely the condition, performance or value of such items. ILMOR reserves the right to retrieve data from the ILMOR Products En- 2011 ILMOR MV8 Owner’s Manual • Page 48... - Page 58 (f) Incidental and consequential damages, including, but not limited to, storage charges, rental charges, inconvenience, loss of time or use, or loss of income. Some states do not allow the exclusion or limitation of incidental or consequential damage, so the above limitation or exclusion may not apply to you; (g) Water pump impellers, water hoses, cooling system anodes or any component determined by ILMOR to be a result of failure of such items; (h) Cost of transporting ILMOR Products or the vessel in which such products are installed to and from designated service facilities for warranty repair and other haul out, launch or towing charges; (i) Oils, lubricants, fuels, or fluids used for normal maintenance and shop supplies such as filtration systems; 2011 ILMOR MV8 Owner’s Manual • Page 49...
- Page 59 5. Warranty Procedure. W ithin ten (10) days from the date of purchase by the origi- nal purchaser of a MasterCraft ski or wakeboard boat containing ILMOR Products, the purchaser shall be required to (i) complete and mail to ILMOR, an ILMOR Marine War- ranty Registration Card; or (ii) complete the on-line warranty registration at the ILMOR Marine web site (www.ILMORmarine.com/warrantyregistration). Warranty claims will not be processed, and are conditioned upon, registration of the purchase with ILMOR Marine. If you believe your ILMOR Products fail to perform in accordance with specifi- cations, have defects in material or workmanship, or are otherwise eligible for coverage under ILMOR Marine’s warranty, you must contact an authorized MasterCraft Dealer within thirty (30) days of discovering the alleged defect. Your MasterCraft Dealer will provide you with the location and contact information of the service facility where you should take your ILMOR Products for inspection and repair. You are solely responsible for transporting your ILMOR Products to the designated service facility. The Master- Craft Dealer may arrange for the necessary inspection and repair to be made on-site, at ILMOR Marine’s sole discretion. For questions regarding warranty service or to obtain 2011 ILMOR MV8 Owner’s Manual • Page 50...
- Page 60 7. Warranty Limitations. THE WARRANTY STATED ABOVE IS A LIMITED WARRANTY AND IS THE ONLY EXPRESS WARRANTY MADE BY ILMOR MARINE WITH RESPECT TO THE ILMOR PRODUCTS. ALL IMPLIED WAR- RANTIES INCLUDING IMPLIED WARRAN- TIES OF MERCHANTABILITY OR FITNESS...
- Page 61 DER CALIFORNIA AIR RESOURCES BOARD REGULATIONS. EMISSIONS RELATED WARRANTIES ARE SET FORTH IN THE OPERATORS MANUAL. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. 2011 ILMOR MV8 Owner’s Manual • Page 52...
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Page 62: Specifications And Service Log
TOP TIER gasoline, 93 octane Fuel System Stabilizer Recommended: Sta-Bil ® Oil Required: ILMOR blended synthetic: SAE Grade 5w30, Viscosity ASTM D445 ACEA Al/Bl, A5/B5; API SM, SL, SJ, EC, CF, CD; ILSAC GF-4 (5 qts. oil change); no oil additives Oil Filter: 94MV8V1021... -
Page 63: Maintenance Requirements
Capacity Fluid Type V-drive 631V 1.56:1 4.6 qts. (4.4L) Automatic transmission fluid (ATF) (1.1 U.S. gal) Direct Drive 63A 1.22:1 4 quarts Automatic transmission fluid (ATF) Direct Drive 45A 1.26:1 2.65 quarts Automatic transmission fluid (ATF) Direct Drive 45C 1.00:1 3.2 quarts Automatic transmission fluid (ATF) Refer to the transmission manual for specific filter requirements. 2011 ILMOR MV8 Owner’s Manual • Page 54... -
Page 64: Service Log
SERVICE Service Date Date Date Date Date Date Engine oil and filter Engine coolant Power steering fluid Transmission fluid Walters V-drive oil Serpentine belt Raw water impeller/ Sea pump Air filter/flame arrestor Engine* Engine timing* Spark plugs* Spark plug wires* Breather hose* PCV valve* Shaft alignment Heat exchanger(s) Zinc anodes 2011 ILMOR MV8 Owner’s Manual • Page 55... -
Page 65: Index
Check the Alternator Belt for Looseness or Damage ......... 16 Check the Coolant Level ................15 Check the Engine Oil Level ..............20 Check the Raw W ater Impeller/Sea Pump ............. 14 Check the Transmission Cooler ..............15 Check the Transmission Fluid/Oil Level ............19 Clean Any Residue ................. 22 Clean the Engine Flame Arrestor/Air Filter ........... 31 Cleaning Engine Compartment and Corrosion Prevention ......... 36 Closed Cooling System, Full ...............7 Concerns, Direct Safety ................2 Considerations, Other ................27 Coolant Draining (Changing Coolant) and Filling ..........34 2011 ILMOR MV8 Owner’s Manual • Page 56... - Page 66 Flame Arrestor/Air Filter, Clean the Engine ..........31 Fluid/Oil and Filter, Change the Transmission ..........30 Fluid/Oil Level, Check the Transmission ............19 Fluid/Oil, Transmission ................13 Flush Coolers ..................35 Flush Raw W ater/Sea Pump System ............21 Fogging Oil, Engine ................40 Fuel and Exhaust Systems for Leaks, Inspect the ..........18 Fuel Requirements ................. 11 Fuel System Treatment ................37 Fuel System ....................5 Fueling the MV8 ..................11 2011 ILMOR MV8 Owner’s Manual • Page 57...
- Page 67 Oil and Filter, Change the Engine ............... 28 Oil Level, Check the Engine ..............20 Oil Pressure (Alarm) ................10 Oil Storage/Winterization ............... 38 Oil Temperature (Alarm)................10 Oil, Engine Fogging ................40 Oil, Engine ..................13 On-Board Diagnostics-Marine (OBD-M) ............43 Open Cooling System ................7 Operation, After Initial Hours of ..............24 Operation, First Hours of ................. 24 Other Considerations ................27 Other Pre-Outing Requirements ..............13 2011 ILMOR MV8 Owner’s Manual • Page 58...
- Page 68 Stopping and New Engine Break-In, Starting ..........23 Stopping the Boat ................... 26 Storage & Winterization ................37 Storage and Winterization, Cooling System ........... 38 Storage/Winterization, Oil ............... 38 Storage/Winterization, Recommissioning After ..........41 System Storage and Winterization, Cooling ........... 38 System Treatment, Fuel ................37 System, Cooling ..................6 System, Electrical ..................8 System, Exhaust ..................5 System, Fuel ...................5 2011 ILMOR MV8 Owner’s Manual • Page 59...
- Page 69 Water Temperature (Alarm) ..............10 Welcome ....................i When the Boat Is Not Used for a While ............12 Winterization, Battery ................40 Winterization, Cooling System Storage and ........... 38 Winterization, Oil Storage/ ..............38 Winterization, Recommissioning After Storage/ ..........41 Winterization, Storage &................37 Wiring, Boat/Engine Interface ..............9 Your W arranty Rights and Obligations (Emissions) ........... 44 Zinc Anodes (Saltwater Applications), Replacing the ........36 2011 ILMOR MV8 Owner’s Manual • Page 60...