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Marinediesel 6,5L V8 Owner's Manual

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Application .............................................................................
Identification ...........................................................................
Break in procedure .....................................................................
Starting procedure .....................................................................
Winter storage..........................................................................
Procedures after winter storage ......................................................
Periodic maintenance .................................................................
Technical maintenance specifications ..............................................
Warranty ................................................................................
Dealer & Service directory ...........................................................
Exhaust manifolds .....................................................................
Supercharger and intercooler system ...............................................
Impeller pump .........................................................................
Raw water and fuel connections ....................................................
Oil filter relocator ......................................................................
2. ENGINE MECHANICAL
Specifications ..........................................................................
Diagnostic ... ...........................................................................
Cylinder block and components .....................................................
Front cover, oilpan and components ................................................
Fuel system components ..............................................................
Serpentine belt system .................................................................
Valve cover replacement ..............................................................
Rocker arm replacement ...............................................................
Valve lifter replacement ..............................................................
Crankshaft Balancer replacement ..... ..............................................
Engine front cover replacement .....................................................
Timing chain replacement ...........................................................
Camshaft replacement ................................................................
Crankshaft rear oil seal replacement ...............................................
Oilfilter adapter replacement ........................................................
Oil pan replacement ..................................................................
Oil pump replacement ................................................................
Fuel injection pump removal ........................................................
Timing chain wear check .............................................................
Engine disassembly and assembly ..................................................
Engine component description .......................................................

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Summary of Contents for Marinediesel 6,5L V8

  • Page 1: Table Of Contents

    TABLE OF CONTENTS 1. GENERAL INFORMATION Application ………………………………………………………………….. Identification ………………………………………………………………... Break in procedure ...………………………………………………………... Starting procedure …………………………………………………………... Winter storage……………………………………………………………….. Procedures after winter storage ……………………………………………... Periodic maintenance ……………………………………………………….. Technical maintenance specifications ………………………………………. Warranty …………………………………………………………………….. Dealer & Service directory ………………………………………………….. Exhaust manifolds …...……………………………………………………… Supercharger and intercooler system ………………………………………..
  • Page 2 3. DIAGNOSTIC INFORMATION Diagnostic Strategy 4. INSTALLATION Important installation notes ..……………………………………………….. Engine ………………………………………………………………………. Air Intake System …………………………………………………………… Fuel System ..………………………………………………………………... Exhaust System ……………………………………………………………. Cooling System ……………………………………………………………... Electrical System ..…………………………………………………………... Predelivery …………………...……………………………………………... Predelivery inspection checklist …………………………………………….. 5. SERVICE INSTRUCTIONS Service information...

  • Page 3: Application

    APPLICATION In 1998, Marinediesel introduced it’s 6,5L V8 supercharged, intercooled marine engine (see drawing below) for light duty commercial and pleasure craft applications. The base engine is manufactured at the General Engine Products ( a division of AM General) 92,000 square foot production facility, located in Franklin, Ohio. The Optimizer 6500 base engine is Euro III and QS 9000 certified.

  • Page 4: Identification

    IDENTIFICATION The Marinediesel engine has a stainless steel serial number tag located on the rear starboard side of the engine block. This serial number tag will reflect the engines six digit serial number starting with MD-######. Serial Number ###### BREAK IN PROCEDURE All Marinediesel engines have a break-in period during the first 20 hours of operation.

  • Page 5: Winter Storage

    It’s not unusual with smoke from the exhaust system just after start-up but this will stop once the engine reaches operating temperature. Glow system will automatically afterglow. Recommended cruising rpm for all Marinediesel engines is 2700-3200rpm although the maximum rated effect is at a higher rpm. It is necessary to choose a propeller that will allow the engine to reach maximum engine rpm at WOT to not inflict unnecessary load on the engine, which could effect longevity and void warranty.

  • Page 6: Procedures After Winter Storage

    thermostat to open and mix the added antifreeze. Never use more than 50% antifreeze. Turn off the engine and drain the raw-water system. At the same time remove the impeller from the impeller pump. Check all hoses, clamps and fittings for wear and leakage, replace if necessary.

  • Page 7: Periodic Maintenance

    This warranty shall apply only to pleasure craft and light-duty craft applications. This warranty shall become effective upon the date of sale to the first purchaser or user of the Product and receipt by MarineDiesel of a completed Sea Trial Registration Form.

  • Page 8: Dealer & Service Directory

    VIII. Claim shall be made under this warranty by delivering the Product for inspection to a Marinediesel dealer authorized to service the Product. If purchaser cannot deliver Product to such authorized dealer, he may give notice in writing to the Company . We shall then arrange for the inspection and repair, provided such service is covered under this warranty.

  • Page 9: Supercharger And Intercooler System

    Raiser bolts Water passage gasket Supercharger and Intercooler System Air induction on Marinediesel SC-engines includes the following parts: x Air intake duct, intake silencer and air filter assembly x Supercharger assembly x Intake assembly with integrated CuNi intercooler x Crankcase ventilation system...
  • Page 10 Air intake adaptor mounts with 6pcs M8 X 25 hexagon socket head bolts. Clamps CDR valve Bolted bracket...
  • Page 11 Supercharger assembly The supercharger assembly connects to the intake manifold using a gasket and 7 pcs M8 X 25 hexagon socket head bolts, torque to 22 Nm, seal with Loctite 270, picture below. gasket Intake assembly with integrated CuNi intercooler...
  • Page 12 Rubber damper on Intercooler tank The intercooler mounts into the rear section of the intake manifold and is then covered by a bronze lid which incorporated an o-ring for sealing. At the end of the intercooler is the intercooler tank that is covered by a rubber damper to ensure that the intercooler does not get in contact with the casting of the intake manifold.

  • Page 13: Impeller Pump

    Impeller Pump Standard UV1 Commercial (high flow) Raw water and fuel inlet connections Fuel return connection Fuel inlet connection Raw water connection Please see installation section starting page 169 for further information...

  • Page 14: Oil Filter Relocator

    Oil filter relocator The oil filter relocator is ordered as an option when ordering the engine. As it is supplied separately it is essential that the oil lines and oil filter are prefilled with oil before starting the engine. The lines should be connected as shown below. To check the function of the remote filter feel the oil lines when engine is running, if they are warm the oil is circulating as it should, if not, stop the engine and recheck the connections.

  • Page 36: Serpentine Belt System

    Drive Belt Replacement Removal procedure: 1. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 2. Remove the drive belt from the drive belt tensioner pulley. 3. Slowly release the tension on the drive belt tensioner arm.
  • Page 152 DIAGNOSTIC STRATEGY The diagnosis of faults related to the MarineDiesel engine involves the following steps: 1 Verify that a condition related to a fault exists 2 Select the condition of the fault 3 Select a system or check that relates to the condition...
  • Page 153 NOTE: Items underlined are the most likely cause of the condition. LOW POWER or LOSS OF POWER PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Incorrect fuel quality (heating ƒ Check specific gravity of fuel (Use fuel energy/purity) quality hydrometer); Inspect and clean fuel tank if needed ƒ...
  • Page 154 NOTE: Items underlined are the most likely cause of the condition. HARD TO START PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Incorrect fuel quality (heating ƒ Check specific gravity of fuel (Use fuel energy/purity) quality hydrometer). Inspect and clean fuel tank, if needed. ƒ...
  • Page 155 NOTE: Items underlined are the most likely cause of the condition. WILL NOT START - COLD PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Incorrect fuel quality (heating ƒ Check specific gravity of fuel (Use fuel energy/purity) quality hydrometer). Inspect and clean fuel tank, if needed. ƒ...
  • Page 156 NOTE: Items underlined are the most likely cause of the condition. WILL NOT START – HOT (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Incorrect fuel return from injection pump ƒ Check fuel return line on top of injection pump for restrictions or debris. ƒ...
  • Page 157 NOTE: Items underlined are the most likely cause of the condition. ROUGH/ERRATIC IDLE PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Operation during extreme ambient ƒ Review normal operating procedures. temperatures (hot/cold) ƒ Binding injection pump throttle cable ƒ Check throttle controls. ƒ Incorrect fuel supply to injection pump (air ƒ...
  • Page 158 NOTE: Items underlined are the most likely cause of the condition. ENGINE MISFIRES PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Incorrect low/fast idle speeds ƒ Consult your dealer service manager. ƒ Incorrect injection pump static timing ƒ Consult your dealer service manager. ƒ Incorrect fuel supply to injection pump (air ƒ...
  • Page 159 NOTE: Items underlined are the most likely cause of the condition. POOR ACCELERATION PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Operation while overloaded or at excessive ƒ Insure boat is properly loaded and operated within RPM limits. ƒ Operation during extreme ambient ƒ Review normal operating procedures. temperature (hot/cold) ƒ...
  • Page 160 NOTE: Items underlined are the most likely cause of the condition. EXCESSIVE WHITE SMOKE PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Incorrect fuel quality (heating ƒ Check specific gravity of fuel (fuel quality energy/purity) hydrometer). Inspect and clean fuel tank, if needed. ƒ Operation with long periods of engine ƒ...
  • Page 161 NOTE: Items underlined are the most likely cause of the condition. BLACK SMOKE UNDER LOAD – HOT (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Operation during extreme ambient ƒ Review normal operating procedures. temperature (hot/cold) ƒ Outside air intake or air filter restricted ƒ...
  • Page 162 BLACK SMOKE AT IDLE (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Worn or damaged supercharger ƒ Consult your dealer service manager. ƒ Air leakage or restriction in air inlet duct or ƒ Check air inlet duct bolt and clamp intake manifold tightness; check intake manifold bolt/stud tightness;...
  • Page 163 EXCESSIVE SMOKE DURING ACCELERATION (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Air leakage or restriction in supercharger ƒ Consult your dealer service manager. inlet duct ƒ Worn or damaged supercharger ƒ Consult your dealer service manager. ƒ Air leakage or restriction in air inlet duct or ƒ...
  • Page 164 GRAY SMOKE (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Air leakage or restriction in air inlet duct or ƒ Check air inlet duct bolt and clamp intake manifold tightness; check intake manifold bolt/stud tightness; disassemble and inspect air inlet duct; with air inlet duct removed, check intake manifold runners.
  • Page 165 EXCESSIVE LUBE OIL COMSUMPTION (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Operation during extreme ambient ƒ Review normal operating procedures. temperature (hot/cold) ƒ Faulty CDRV operation ƒ Consult your dealer service manager. ƒ Leaking crankcase ventilation system ƒ Inspect system for oil leakage; repair or (pipes/hoses) replace damaged parts, if needed.
  • Page 166 EXCESSIVE FUEL CONSUMPTION (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Restricted exhaust system ƒ Inspect exhaust sytem for collapsed pipes or muffler ƒ Incorrect injection pump static timing ƒ Consult your dealer service manager. ƒ Incorrect fuel supply to injection pump ƒ Consult your dealer service manager. ƒ...
  • Page 167 FUEL OR LUBE OIL LEAKS (Continued) PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Lubrication component package ƒ Inspect sealing surfaces and areas for signs of oil leakage: -Rocker arm covers -Front cover -Oil fill pipe -Oil pump drive/engine speed sensor -Cylinder case passage plugs -Oil filter mounting -Oil cooler pipes/hoses -Oil pan...
  • Page 168 LUBE OIL CONTAMINATED PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Air/dirt ingestion at oil leakage areas ƒ Inspect sealing surfaces and areas for signs of oil leakage ƒ Leaking crankcase ventilation system ƒ Inspect system for oil leakage; repair or (pipes/hoses) replace damaged parts, if needed COOLANT CONTAMINATED PROBLEM CORRECTION/FURTHER DIAGNOSIS...
  • Page 169 HIGH OIL SUMP TEMPERATURE PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Incorrect oil level (high/low) and quality ƒ Remove or add oil to correct level; drain (grade/viscosity/purity) and refill crankcase, if needed. ƒ Operation during extreme ambient ƒ Review normal operating procedures. temperature (hot/cold) ƒ...
  • Page 170 HIGH OIL PRESSURE PROBLEM CORRECTION/FURTHER DIAGNOSIS ƒ Operation during extreme ambient ƒ Review normal operating procedures temperature (hot/cold) ƒ Sticking oil pump pressure regulator valve ƒ Check oil pressure; consult your dealer service manager. ƒ Inaccurate oil pressure gauge operation ƒ...

  • Page 171: Specifications

    ------------- IMPORTANT INSTALLATION NOTES---------------- These Notes are very important and the most common cause of problems historically on Marinediesel engines, for further information review Section 2, Installation of the Owners Manual. x Please make careful notes on mounting battery cables of the correct dimensions, failure to comply with this will make the engine difficult to start.
  • Page 172 NOT run exhaust through the sterndrive as this will lead to excessive backpressure. x It is MANDATORY that all MARINEDIESEL engines are propped according to MARINEDIESEL recommendations. Over-propping of the boat induces excessive loading of the engine which will generate excessive exhaust temperatures and resulting reduction of engine longevity.
  • Page 173 Section 1 – ENGINE Engine Mounting Engine Bed Flexible Engine Mounting Engine Mounts Engine Alignment Checking Stringer Height Suspending the Engine Final Adjustment Mount Height Power Steering Hose Routing Exhaust Hose Routing Owners Manual Section 2 - Engine...

  • Page 174: Engine Mounting

    Marindiesel engines are generally equipped with pedestal-type, flexible front engine mounts Flexible Engine Mounting Generally, Marinediesel engines are equipped with pedestal type front engine mounts. All front mounts include provisions for isolating engine vibrations. The rear of the engine mounts to the stern drive transom plate or transmission.

  • Page 175: Engine Mounts

    Engine Mounts Front engine mounts are adjustable and must rest on boat stringers. 3/8 in. lag screws or bolts, depending upon stringer construction, retain engine mount pedestal to stringer. Grade and length of lag screws or bolts, must be selected based on stringer material and anticipated loading forces. Adjustment nut is turned counterclockwise to raise front of engine, or clockwise to lower front of engine.

  • Page 176: Engine Alignment

    ENGINE ALIGNMENT Checking Stringer Height Ensure that the stringers are equal in height before installing the engine. Tying a string from the port front mount location to the starboard rear engine mount on transom assembly or transmission may check this. Another string should be tied from starboard front to port rear.

  • Page 177: Suspending The Engine

    Suspending The Engine Front and rear lifting eyes on the engine are provided to allow attachment of a suitable sling. The engine can then be lifted into position (in boat) using an overhead hoist. Before lifting remove the plastic engine cover in order not to damage it. Engine Lifting brackets -Front -Rear...
  • Page 178 Final Engine Mount Height IMPORTANT: Finished boat stringer must position engine so that a minimum mount adjustment exists after front mount is adjusted down to stringer. This allows for future adjustments. During final engine mount adjustment, the mounts are temporarily adjusted until they rest on the stringers. Hoist tension is relieved so that the engine settles onto the stringers and the mounts are appropriately fastened to stringers.

  • Page 179: Power Steering Hose Routing

    POWER STEERING HOSE ROUTING IMPORTANT: When installing power steering hoses observe the following. Make hydraulic connections as quickly as possible to prevent fluid leakage. Be careful not to cross-thread or over tighten fittings. Power steering fluid hoses must be purchased separately. Proper routing and installation of the hoses is required to avoid problems related to power steering system.

  • Page 180: Exhaust Hose Routing

    EXHAUST HOSE ROUTING Exhaust hose routing is dependent upon the various engines and boat designs. However, in all cases, care must be exercised in the proper installation of an exhaust hose, or failure may occur. CAUTION Avoid exhaust hose failure. Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots that could eventually result in burned-through exhau hoses.
  • Page 181 Merc Style - Through Propeller Exhaust (Volvo Y-pipe need to be cut to duplicate this) Owners Manual Section 2 - Engine...
  • Page 182 Section 2 – AIR INTAKE SYSTEM Engine compartment Engine compartment ventilation General information Combustion air requirements Owners Manual Section 2 - Engine...

  • Page 183: Engine Compartment Ventilation

    ENGINE COMPARTMENT WARNING Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when constructing the engine compartment. ENGINE COMPARTMENT VENTILATION General Information According to Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations the engine compartment ventilation system has multiple tasks. Including: x Supply the engine with combustion air.
  • Page 184 Combustion Air Requirements Engine compartments with natural draft ventilation must have vent openings of sufficient size and location to accomplish the tasks previously outlined. IMPORTANT: The size of ventilation openings must be increased if any auxiliary equipment is located in the engine compartment. The combustion air requirement (per engine) for the specified engines at Wide Open Throttle is given in the following table.
  • Page 185 Section 3 – FUEL SYSTEM Fuel delivery system Fuel tank Fuel lines Additional fuel filter usage Fuel line fitting installation Fuel return fitting requirements Water separating fuel filter Fuel system temperature and pressure drop Owners Manual Section 3 - Engine...

  • Page 186: Fuel Tank

    Fuel Tank The Fuel Tank is an integrated component of the boat. Marinediesel makes no attempt in this manual to cover all aspects of design and integration of the fuel tank in the boat due to the broad range of possible configurations. Refer to information from the tank manufacturer as well as boating standards (NMMA, ABYC, etc.) and Coast Guard...

  • Page 187: Fuel Lines

    Fuel Tank Bottom Versus Fuel Inlet Height (Measured from bottom of fuel tank to height of fuel inlet fitting.) Less than 20 in. (< 508 mm) Not generally a problem May be suspect of causing fuel delivery 20-40 in. (508-1016 mm) system problems.
  • Page 188 SPECIAL INFORMATION ABOUT ADDITIONAL FUEL FILTER USAGE CAUTION The engine fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together. Do not install additional fuel filters and/or water separating fuel filters between fuel tank and engine. The installation of additional filters may cause: x Fuel Vapor Locking x Difficult Warm-Starting...
  • Page 189 FUEL RETURN FITTING REQUIREMENTS x Return fuel line is recommended to be 3/8in (10mm) and must end freely in the top of the fuel tank. There must be no restriction on the return fuel system. WATER SEPARATING FUEL FILTER The engine must be installed with the water separating fuel filter supplied with the engine.
  • Page 190 General Information The power output of an engine can be limited by the amount of restriction in the boat’s fuel supply system. The Marinediesel specifications for the boat’s fuel system performance regarding fuel inlet are: Specifications For Fuel System Performance...
  • Page 191 Section 4 – EXHAUST SYSTEM Important information Methods of measuring for raisers Straight edge method Through the hull Exhaust Exhaust connections Exhaust backpressure Owners Manual Section 6 - Engine...

  • Page 192: Important Information

    Damage caused by water in the engine will not be covered by the Marinediesel warranty, unless this damage is the result of defective parts or workmanship on the part of Marinediesel.
  • Page 193 4. The difference between these two measurements is the exhaust elbow height above the water line. Refer to Measuring Procedure and compare measurement to Marinediesel specifications. Straight Edge Method For Measuring Exhaust Elbow Height -Measurement Between Straight Edge And Top Of Exhaust Elbow...
  • Page 194 On All Applications: Minimum Exhaust Elbow Height from Top of Elbow to Waterline Model Measurement All Models 13 in. (330 mm) Additional Requirements for Through The Hull and Through The Transom Exhaust System Applications: Minimum Continuous Downward Slope (Exhaust Hoses, Collector, Etc.) Model / Application Measurement Owners Manual Section 6 - Engine...
  • Page 195 The exhaust system on Marinediesel engines must have a minimum of 4 in. (102 mm) of vertical drop between the exhaust elbow outlet and the exhaust outlet of the boat.
  • Page 196 Exhaust Connections Important Information CAUTION Avoid exhaust hose failure. Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots, which could eventually result in burned-through exhaust hoses. Exhaust hoses and/or tubes must be correctly connected to exhaust elbows so that they do not restrict the flow of discharge water from exhaust elbow.

  • Page 197: Exhaust Back Pressure

    Marinediesel specifies the following maximum backpressure, which can be measured using the test outlined following.
  • Page 198 Section 5 – COOLING SYSTEM General information Seawater supply and hose connections Through the hull or transom Seacock Seawater filter Seawater pump and bracket Drive belt routing Water heaters Owners Manual Section 6 - Engine...

  • Page 199: Specifications

    General Information Marinediesel engines are closed (fresh water) cooled. Closed cooled engines have the engine block and select other components cooled by a mixture of water and antifreeze. Cooling system components must be constructed and sized appropriately to supply the engine with sufficient water under all operating conditions.
  • Page 200 THROUGH THE HULL OR TRANSOM On the engine the seawater cooling hose connects to a water pickup that is mounted through the hull or transom of the boat. Refer to instructions provided by the seawater pickup manufacturer, or Installation Manual supplied with product. A seacock (water inlet valve) is recommended.
  • Page 201 THROUGH THE STERNDRIVE UNIT Seawater inlet hose through sterndrive is NOT recommended. Any resulting engine overheat problems will NOT be covered by Marinediesel’s warranty. THROUGH THE HULL OR TRANSOM Seawater pickup hose must be obtained separately if using a through the hull or through the transom seawater pickup.
  • Page 202 SEAWATER PUMP AND BRACKET The seawater pumps (STD & UV1) are installed and secured with hardware shown. Screws torque to 30 lb-ft (41 Nm). Standard UV1 Commercial HV -Seawater Pump Bracket -Seawater Pump (With Serpentine Belt Pulley) –8mm screws with washer Owners Manual Section 6 - Engine...
  • Page 203 DRIVE BELT ROUTING Barracuda With Power Steering SC With Power Steering Barracuda Without Power Steering SC Without Power Steering Owners Manual Section 6 - Engine...
  • Page 204 Water Heaters Important Information IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be met: x Supply hose (from engine to heater) and return hose (from heater to engine) MUST NOT EXCEED 5/8 in. (16 mm) ID (inside diameter). x Make heater connections ONLY at locations indicated in the following information.
  • Page 205 Section 6 – ELECTRICAL SYSTEM Electrical connections Battery Battery cables Accessories Electrical plug harness Warnings system and alarms Engine monitoring panel Wire color Owners Manual Section 6 - Engine...

  • Page 206: Electrical Connections

    Electrical Connections Battery GENERAL INFORMATION IMPORTANT: Boating industry standards (ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing battery. Be sure battery cable installed meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. IMPORTANT: It is recommended (required in some countries) that battery be installed in an enclosed case.

  • Page 207: Battery Cables

    Battery Cables GAUGE Battery cable gauge will change based on the length of the cable needed. Be sure to measure the length of the battery cables from battery to engine so the gauge can be determined by the chart shown. Select proper gauge (size) positive (+) and negative (–) battery cables, using chart: Cable Length Cable Gauge Up to 7-1/2 ft.
  • Page 208 Accessories CONNECTION POINT Up to 3 accessory leads can be connected to the positive battery terminal (B+) stud on the starter motor. These leads must be equipped with the appropriate current overload protection. Refer to the ABYC standards or applicable industry standards for more information.
  • Page 209 A plug receptacle is located on the engine that will allow the instrumentation wiring harness to be connected to the engine wiring harness. The receptacle is designed for Marinediesel wiring. A hose clamp is required to prevent separation and seal out moisture. Install hose clamp at location shown.

  • Page 210: Predelivery

    Warning System From 2006 all Marinediesel engines are equipped with a panel integrated Warning System. The light and a audible buzzer comes on when engine oil pressure is too low or engine coolant temperature is too high. If warning system is activated, immediately shut down the engine by turning the key to off position.
  • Page 211 Instrument Panel A-type (IP65) Function Standard a – L.O. pressure meter b – Tachometer with hour meter c – C.W. temperature meter d – Instrument light switch e – Fuse f – Volt charge meter g – Alarm lamp/buzzer charging h –...
  • Page 212 Section 7 - Predelivery Predelivery Preparation Battery connection Power steering Boat-in-the-water-test Engine Idle speed Wide open throttle test Important installation notes Predelivery checklist Cold weather or extended storage draining instructions Owners Manual Section 7 - Engine...

  • Page 213: Predelivery Preparation

    Predelivery Preparation NOTICE Before starting Predelivery, completely read and thoroughly understand this Owners/Applications Manual supplied with the engine package. Once the engine package installation is complete, the following final steps should be taken to prepare engine package for delivery to the customer. It is the boat manufacturer’s responsibility to perform these procedures, or to make arrangement with the dealer to have these procedures completed.
  • Page 214 Power Steering IMPORTANT: Use only Dexron III automatic transmission fluid (ATF) in power steering system. CAUTION DO NOT RUN POWER STEERING DRY, or pump will be damaged. 1. Position drive unit so that it is straight back. 2. Remove fill cap from power steering pump reservoir and check fluid level. 3.
  • Page 215 WARNING Do not leave helm unattended when making test with boat in the water. 1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight. 2. Check drive belt tension. 3. Test warning system. 4. Start engine and run at idle rpm until water temperature is normal. 5.
  • Page 216 11. Check power steering fluid level. a. Turn engine OFF. b. Remove cap/dipstick from power steering pump. Check fluid level and add as necessary. Cap/Dipstick -Full When COLD Line -Full When HOT Line Boat-ln-The-Water Tests CAUTION Avoid engine damage. Ensure that cooling water is supplied to the engine if it will be operated with the boat out of the water.
  • Page 217 WIDE OPEN THROTTLE TEST IMPORTANT: To operate engine at full throttle before the break-in period is complete, follow this procedure. x Start engine and operate at idle rpm until normal operating temperature is reached. x Run boat up on plane. x Advance engine rpm in 200 rpm increments, until engine reaches its maximum rated rpm.
  • Page 218 ------------- IMPORTANT INSTALLATION NOTES------------- These Notes are very important and the most common cause of problems historically on Marinediesel engines, for further information review Section 2, Installation of the Owners Manual. x Please make careful notes on mounting battery cables of the correct dimensions, failure to comply with this will make the engine difficult to start.
  • Page 219 We have found that adding the through hull inlet ensures adequate water flow to the engine and prevents issues arising in the future. The MARINEDIESEL warranty does NOT cover engine overheat related problems. x It is HIGHLY recommended that the engine exhaust be run through the transom and NOT run exhaust through the sterndrive as this will lead to excessive backpressure.

  • Page 220: Predelivery Inspection Checklist

    Predelivery Inspection Checklist (required for warranty registration) Check/ Check/ Applic. Adjust Applic. Adjust Check before Running On the water Test Double hose clamps on Starter neutral safety switch all fuel lines, tightened operation Min 10mm ID fuel hose Instruments operation Min 8mm ID return hose Oil leaks + oil pressure Return hose exits at top...
  • Page 221 Check/ Check/ Applic. Adjust Applic. Adjust Check before Running After on water test Remote oil filter filled Fuel, oil, coolant, water and with oil, if applicable. fluid leaks Transmission/drive oil Oil and fluid levels level + Belt tension Diesel primed to mech fuel Re-torque all clamps incl pump and fuel filter exhaust...
  • Page 222 Check/ Check/ Applic. Adjust Applic. Adjust Check before Running After on water test Double hose clamps on Go through warranty and all exhaust hoses, service information with tightened customer Down angle on exhaust hose from raiser min 7deg Exhaust through drive? Y/N:________ Owners Manual Section 7 - Engine...
  • Page 223 Installation finish date DD/MM/YY: _____________________________________ Boat Type/make/build year: _____________________________________ Boat overall length: _____________________________________ Boat weight: _____________________________________ Installed MD engine serial no: _____________________________________ Drive/gear including ratio _____________________________________ Propeller diam/pitch/make: _____________________________________ Cruise speed mph/knots@rpm: _____________________________________ WOT mph/knots@rpm _____________________________________ Installed by: _____________________________________ Inspected by: _____________________________________ Inspection date DD/MM/YY: _____________________________________...

  • Page 224: Cold Weather Or Extended Storage Draining Instructions

    IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system. IMPORTANT: Marinediesel recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 225: Service Instructions

    If this is not followed it can cause oil to be diluted by soot and catastrophic engine failure can occur that would not be covered by warranty. Please contact your local Marinediesel representative if you have any questions related to this. Below are the different periodic maintenance procedures in more detail, for information...
  • Page 226 Check for oil leaks Very similar procedure to checking for oil leaks, if the bilge is kept clean then a leak will be clearly visible in the bilge water. If not possible start with a flashlight and a mirror to look around the oil pan region and then a clean white towel to verify any suspected leaks.
  • Page 227 Above photo showing tensioner without load and belt removed, arrow show marking point. Check coolant level in heat exchanger Remove the heat exchanger pressure cap. And make sure you have the correct coolant level; the level should be approx 10mm under maximum and just above the pipes inside the heat exchanger.
  • Page 228 Change engine oil We recommend the use of a vacuum canister (photo below) for removing the oil but a manual or electric oil drain pump can also be used. Oil change Procedure: Step 1: Make sure the engine is at or close to operating temperature and shut down the engine. Locate the engine oil dipstick on the port side of the engine, clearly seen in yellow on the photo below.
  • Page 229 Step 2: Remove the oil dipstick from the dipstick tube and insert the plastic tube from the oil drain pump or vacuum canister. Owners Manual Section 7 - Engine...
  • Page 230 Step 3: Make sure that the plastic tube reaches all the way to the bottom of the oil pan or it will not evacuate all the oil. Drain all the oil from the engine. Step 4: Remove the plastic fuel line and insert the oil dipstick back into the tube. Change oil and filter and check on the dipstick that the correct level is achieved before starting the engine.
  • Page 231 Change oil filter Marinediesel engines use single or twin spin-on lube oil filters. You may require a tool to remove them. It is very important to fill up the new filters with oil (completely full) before mounting them on the bracket. If the filters are not filled with oil the engine will run without lubrication for some time before the filters fill up and this can lead to catastrophic engine failure.
  • Page 232 This is a very straight forward procedure that does not need further description. Change Impeller There are two types of impeller pumps offered with Marinediesel’s 6.5L engines. One standard impeller pump and then the UV1 commercial high flow unit. The two pumps use different impellers.
  • Page 233 UV1 Commercial (high flow) Change fuel filter All Marinediesel engine are shipped with engine mounted fuel filters. In some installations the boat builder may opt to relocate this to a location that is more accessible for service. This is a simple spin on filter and can easily be removed with an oil filter tool once located.
  • Page 234 On all installations there should always be a fuel prefilter and the element of this should also be replaced periodically. Note: If using JP5 or JP8 fuel please contact Marinediesel as these will and must have a specific prelubricated JP filter.
  • Page 235 Change glow+ start relays and slave relay on port cylinder head The service book will inform you when to replace these relays. Glow relay shown to the right and the slave relay to the left (on port head) Owners Manual Section 7 - Engine...
  • Page 236 On back of starboard cylinder head 1. Glow relay 2. starter relay On back of port cylinder head Bosch slave relay shown in the photo above. When replacing the relays, make sure that there is no corrosion on the connectors and use some grease as corrosion protection when assembling.
  • Page 237 Change antifreeze/coolant in the closed cooling system For this you need to drain the entire closed cooling system on the engine are replace with a new mix of 50% glycol (antifreeze) and 50% clean fresh water. The glycol should be used even when operating in tropical climates as it has other beneficial effect such Increases cooling capacity.
  • Page 238 Check operation of glow system Start with a cold engine. Turn the ignition key one step (do not engage the starter motor) this will turn on the glow sequence. First there will a long glow segment of approx 7-10 seconds (glow light on and a click noise from the glow relay on the engine) then followed by 3-5 short glow segments.
  • Page 239 Just pull the thermostats out, replace them and bolt it back up. The only seal that is vital is the housing cover so it won't leak coolant. Note of interest: Look at a thermostat carefully and you'll see a small bleed hole, which would pass more coolant than any leak around the edge would.
  • Page 240 Check timing To check this you will need a diesel strobe timing light tool. There is a timing market on the harmonic balancer on the front of the engine. Timing should be set at 6-7 degrees at 1200rpm. If timing is incorrect then you need to loosen the three nuts on the injection pump and set the timing.
  • Page 241 Flush engine cooling system including oil cooler This is normally down at the same time as changing the coolant in the closed cooling system. Flush both the closed cooling system and the raw water system. Visual check and pressure test of intercooler Remove the intercooler core from the engine.
  • Page 242 Change injectors Remove the exhaust manifolds as these will be in the way of obtaining access to the injectors. Then loosen the injector line nut from the injector body. Then bend the injector lines to the side carefully and remove the injectors. Make sure you change the cupper seal ring when installing the new injectors.
  • Page 243 Re-torque all hose clamps Re-torque clams as they can have loosened over time from vibration or deformation of rubber hoses. Replace heat exchanger pressure cap The seal and spring has limited life as it will wear from frequent heat cycles. Owners Manual Section 7 - Engine...
  • Page 244 Re-torque engine mounts These can become loose over time and needs to be checked for proper torque. It is essential to check the alignment of the engine/drive package at the same time. Adjustment nut is turned counterclockwise to raise front of engine, or clockwise to lower front of engine. Typical Front Mount -Nut And Lock washer -Adjustment Nut...
  • Page 245 (Sales Contract) for the Product to be serviced. Warranty claims will not be accepted by the dealer until the original date of sale/delivery and Product serial number can be verified. It is a condition for the continuation of this warranty that the Product be taken to an authorized Marinediesel Service Dealer, after 100 hours of engine operation, but not later than 150 hours, for required checks and adjustments.
  • Page 247 Marinediesel Peasurecraft Service book Service done by: Engine Serial No. Hrs on engine: Date: Comments: Scheduled maintenance for the following running hrs Or after number of years whichever occurs first Scheduled maintenance marked by “shadowed” field Check for water leaks...
  • Page 248 Marinediesel Pleasurecraft Service book Service done by: Engine Serial No. Hrs on engine: Date: Comments: Scheduled maintenance for the following running hrs Or after number of years whichever occurs first Scheduled maintenance marked by “shadowed” field Check for water leaks...

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