4.3L/5.3L/6.2L/LT4

ENGINE OWNER’S MANUAL

VERSION 4 Table of Contents

Section 1: Introduction Section 13: Installation Instructions Proposition 65...... 1 Full Closed Inboard Jet Engines...... 23 Engine Compartment...... 41 Safety Warnings...... 1 Engine Mounting...... 41 Section 10: Engine Maintenance Replacement Parts...... 1 Engine Rotation...... 41 Scheduled Maintenance by Owner...... 24 Safe Boating...... 2 Engine Bed...... 41 Scheduled Maintenance by Qualified Technician...... 25 Warranty...... 2-5 Cooling System...... 41-42 Oil Change...... 26 Emission-Related Installation Instructions...... 42 Section 2: Safe Boating Oil Filters...... 27 Exhaust Piping...... 42 Carbon Monoxide Exposure...... 6 Flame Arrestor...... 28 Electrical Connection...... 43 G-Force Fuel System...... 28 Section 3: Engine Identification Batteries...... 43 Battery Cables...... 29 Engine Type...... 7 Dual Engines...... 43 Multiple Engine Battery Precautions - EFI...... 29 Model Specifications...... 8 Battery Isolators...... 43 Tension...... 29 Engine Battery Specifications...... 44 Section 4: Electronic Sequential Sea Water Pump Impeller Replacement...... 29 Battery Cable Length Requirements...... 44 Information...... 9 Closed Cooling System...... 30 Special Fuel Instructions for 6.2 550 HP Engines...... 44 illing losed ooling ystem ection ngine larms and nstrumentation F C C S ...... 30-31 S 5: E A I lT4 airBoat nstallation ...... 45 Digital Alarms...... 10 Section 11: Engine Diagnostics and Codes...... 32-34 Adapter Harness...... 46 Instrumentation...... 11 eater onnections Section 12: Trouble Shooting H C ...... 47 restart hecklist Section 6: SSVEC Fuse and Relay Enclosure...... 12-15 Engine Will Not Turn Over...... 35 P C ...... 48 ngine ranks ut ill ot tart Section 7: Precautions E C B W N S ...... 35 Warranty Registration Transfer...... 49 Engine Runs Poorly at High RPM...... 36 Oil Level...... 16 Log...... 50-52 igh peed iss ...... 16 H S M ...... 36 Fuel System - Rich...... 37 Section 8: Engine Operating Instructions Fuel System - Lean...... 37 Gasoline Requirements...... 17 Poor Fuel Economy...... 37 Oil Requirements...... 17 Engine Starts and Stops...... 38 Starting Engine EFI...... 17 Oil Pressure - Low...... 38 Engine Break-In/25 Hour Inspection...... 17-18 Oil Pressure - High...... 38 Section 9: Winterization Excessive Oil Consumption...... 39 ...... 19 Engine Overheating...... 39 Full Closed Cooled Engines...... 20 Water in Engine or Base...... 40 i www.MarinePowerUSA.com 1. Introduction MARINE POWER would like to thank you again for your operation, are major accident prevention measures. Replacement Parts purchase. The pleasure and peace of mind derived from Use of replacement parts (i.e. automotive, after-market, your new engine is in direct proportion to the amount of Safety Warnings etc.) in the electrical, ignition and fuel systems, which care that it is given. We have tried to include as much are not U.S. Coast Guard approved, could cause a fire or as possible in our Engine Owner’s Manual to help you DANGER explosion hazard and must be avoided. as the customer. READ THIS MANUAL THOROUGHLY DANGER Signals serious damage, failure or breakdown of AND COMPLETELY before attempting to operate your DANGER Always request that genuine MARINE POWER equipment; severe injury or high probability of death to MARINE POWER engine. We ask that you become Engine replacement parts be used in any repairs or the user if proper precautions are not taken. This signal familiar with the components and the maintenance maintenance being performed on your engine(s). word is applied in extreme situations. schedules. If you have any questions or concerns regarding this manual or your newly purchased MARINE WARNING POWER Engine, DANGERplease feel free contact your nearest WARNING DANGER MARINE POWER dealer or . Electrical, ignition and fuel system components are Indicates a potential hazard which could result in per- designed and manufactured to comply with U.S. sonal injury. Proposition 65 Coast Guard rules and regulations to minimize the CAUTION possibility of fire or explosion hazard. WARNING CAUTION WARNING The engine exhaust from this product contains Indicates a hazard which could result in damage to chemicals known to the State of California to cause equipment. cancer, birth defects or other reproductive harm.

“Safety Warnings” and additional information or WARNING: The LT4 Is a Premium 93 Octane REQUIRED engine. The engine will operate at instructions areCA used to UTalert the installer/operatorION of significantly reduced power output with octane levels downCA to 90. OperatingUT IONthe LT4 on fuel possible safety hazards in performing certain service or below 90 Octane can result in engine damage and or failure! Such failure will not be covered maintenance procedures incorrectly or carelessly. under warranty! These “Safety Warnings” alone cannot eliminate the hazards that they signal. Strict compliance with these warning instructions while performing service and maintenance procedures, plus “common sense”

1 1. Introduction Safe Boating your protection. CALIFORNIA AND U.S. ENVIRONMENTAL PROTEC- TION AGENCY EMISSIONS CONTROL WARRANTY The waterways are becoming increasingly crowded WARRANTY REGISTRATION MUST BE RECEIVED STATEMENT and, in order to enjoy them safely, the operator should WITHIN 10 DAYS AFTER DATE OF PURCHASE BY FIRST acquaint himself/herself with safe boating practices. OWNER. Your Warranty Rights and Obligations Boating safely and seamanship courses are offered by Please read the Limited Warranty document that is The California Air Resources Board, U.S. E.P.A., and the following national and state organizations: included with your engine registration papers and in MARINE POWER HOLDING, LLC are pleased to explain • Power Squadrons this manual. This document explains your warranty the emission control system warranty on your Inboard coverage. Please note that no warranty repairs are • Coast Guard Auxiliary engine. New Inboard engines must be designed, built to be performed without prior authorization from the and equipped to meet California and EPA’s stringent • Red Cross Marine Power Distributor in your area. Contact your anti-smog standards. MARINE POWER HOLDING, LLC • State, provincial or local agencies in charge of selling dealer directly for any required warranty repairs. must warrant the emission control system on your water safety enforcement For more information, you may also visit our web site at Inboard engine for the periods of time listed on the next www.marinepowerusa.com. page, provided there has been no abuse, neglect or MARINE POWER recommends that all power boat improper maintenance of your inboard engine. operators attend one of these courses. Again, thanks for choosing MARINE POWER. Your emission control system may include parts such To help locate a course being offered near you, as fuel injection system, the and contact Boat U.S. Foundation’s toll-free national boat- . Also included may be hoses, belts, ing safety hotline, 1-800-336-BOAT, and in Virginia, connectors and other emission-related assemblies. 1-800-245-BOAT. Where a warrantable condition exists, MARINE POWER The Federal Boat Safety Act of 1971 requires that HOLDING, LLC will repair your inboard engine at no cost registration of marine products sold in the United to you, including diagnosis, parts and labor. States be maintained by the manufacturer and dealers of those products. It is imperative that MARINE POWER HOLDING, LLC receive your WARRANTY REGISTRA- TION/SEA TRIAL form properly completed for warranty purposes and to comply with federal regulation. This registration also enables us to contact you, if it should become necessary, to change or improve the product for

2 www.MarinePowerUSA.com 1. Introduction Manufacturer’s Warranty Coverage MARINE POWER DOES NOT AUTHORIZE ANY PERSON TO CREATE FOR MARINE POWER ANY OBLIGATION OR Engine Type Power Electronic Mechanical LIABILITY OTHER THAN THAT STATED IN THE LIMITED Rating Components Components WARRANTY. UNDER NO CIRCUMSTANCES SHALL Conventional - OEM Less than or equal to 3 Years or 480 Hours 3 Years or 480 Hours MARINE POWER BE LIABLE TO THE CUSTOMER OR 373 kW (500 HP) ANY OTHER PERSON FOR ANY CONSEQUENTIAL, INCIDENTAL, ECONOMIC, DIRECT, INDIRECT, GENERAL, Hi-Performance - OEM Between 373 kW (500 HP) 3 Years or 150 Hours 3 Years or 150 Hours OR SPECIAL DAMAGES ARISING OUT OF ANY BREACH and 485 kW (650 HP) OF WARRANTY, EXPRESSED OR IMPLIED. Complete Engine Repower Less than or equal to 2 Years or 300 Hours 2 Years or 300 Hours 373 kW (500 HP) Owner’s Warranty Responsibilities Complete Engine Repower Between 373 kW (500 HP) 1 Year or 150 Hours 1 Years or 150 Hours As the Inboard engine owner, you are responsible for and 485 kW (650 HP) the performance of the required maintenance listed in your owner’s manual. MARINE POWER HOLDING, Special Applications All 1 Year or 150 Hours 1 Years or 150 Hours LLC recommends that you retain all receipts covering THIS AGREEMENT GIVES YOU SPECIFIC LEGAL RIGHTS, do not allow the exclusion or limitation of incidental maintenance on your inboard engine, but MARINE AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY or consequential damages, so the above limitation and POWER HOLDING, LLC cannot deny warranty solely FROM JURISDICTION TO JURISDICTION. exclusion may not apply to you. This warranty gives you for the lack of receipts or your failure to ensure the performance of all schedule maintenance. MARINE THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED specific legal rights and you may also have other rights which vary from state to state and country to country. POWER highly recommends that the selling dealer WARRANTIES, INCLUDING THOSE OF MERCHANTABI- do Warranty Registration along with a completed LITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE THE FOREGOING REMEDIES ARE EXCLUSIVE. MARINE Statement of Sea Trial in order to facilitate any LIMITED TO THE APPROPRIATE WARRANTY PERIOD POWER MAKES NO OTHER EXPRESS WARRANTY. warranty work necessary in the future. IN THE ABOVE TABLE, OR TO THE EXTENT PERMIT- MARINE POWER SHALL IN NO CIRCUMSTANCES BE TED BY LAW, ANY AND ALL IMPLIED WARRANTIES LIABLE IN CONTRACT, IN TORT OR OTHERWISE FOR As the Inboard engine owner, you should however be ARE EXCLUDED. LIABILITY FOR INCIDENTAL OR CON- SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAG- aware that MARINE POWER HOLDING, LLC may deny SEQUENTIAL DAMAGES ARE EXCLUDED TO THE EX- ES, WHETHER OR NOT FORESEEABLE. NO EMPLOYEE you warranty coverage if your Inboard engine or part TENT EXCLUSION IS PERMITTED BY LAW. Some states OR REPRESENTATIVE OF MARINE POWER IS AUTHO- has failed due to abuse, neglect or improper mainte- or countries do not allow limitations on how long an RIZED TO MODIFY THIS WARRANTY, OR MARINE nance or unapproved modifications. implied warranty lasts, and some states or countries POWER’S STANDARD WARRANTY FOR ANY PRODUCT. You are responsible for presenting your Inboard engine 3 1. Introduction to a MARINE POWER HOLDING, LLC distribution center first retail owner. However, in no event shall the Power at a warranty station. Any such part repaired as soon as a problem exists. The warranty repairs will duration of this Warranty exceed three (3) years or replaced under warranty will be warranted for be complete within a reasonable amount of time, not to measured from the original retail sale date. the remainder of the period to the first scheduled exceed 30 days. 3. Any warranted part that is not scheduled for replacement point for the part. 1. MARINE POWER HOLDINGS, LLC (“Marine replacement as required maintenance in the 6. Repair or replacement of any warranted part Power”) warrants to the first owner purchasing at written instructions in the Owner’s Manual will be under the warranty provisions of the article will be retail and all subsequent owners, of every Marine warranted for the appropriate warranty period in performed at a warranty station at no charge to Power Inboard marine engine manufactured after the above table. If the part fails during the period the owner. Warranty services and repairs will be January 1, 2008, that the emissions control devices of warranty coverage, the part will be repaired or provided at all Marine Power distribution centers on Marine Power Inboard marine engines are free replaced by Marine Power at a warranty station. and trained marine dealers. from defects in materials and workmanship when Any such part repaired or replaced under warranty 7. The engine owner will not be charged for diagnos- manufactured and will remain so for the stated will be warranted for the remainder of the period. tic labor that is directly associated with diagnosis period in the above table. Marine Power warrants 4. Any warranted part that is scheduled only for of a defective, emission related warranted part, that each Marine Power Inboard marine engine and regular inspection in the written instructions in the provided that such diagnostic work is performed at factory installed accessories designed, built and Owner’s Manual will be warranted for the appropri- a warranty station. equipped with all applicable regulations adopted ate warranty period in the above table. A statement 8. Marine Power is liable for damages to other engine by the Air Resources Board pursuant to its authority in such written instructions to the effect of “repair in Chapters 1 and 2, Part 5, Division 26 of the Health components proximately caused by a failure under and replace as necessary” does not reduce the warranty of any warranted part. and Safety Code; and the U. S. Environmental period of warranty coverage. Any such part repaired Protection Agency pursuant its authority in or replaced under warranty will be warranted for 9. Throughout the appropriate warranty period in the Chapter 9 of Title 5 of the U.S. Code to be free from the remaining warranty period. table from the previous page Marine Power will defects in materials and workmanship that cause the maintain a supply of warranted parts sufficient to 5. Any warranted part that is scheduled for replace- failure of a warranted part to be identified in all meet the expected demands for such parts. material respects to that part as described in the ment as required maintenance in the written engine manufacturer application for certification. instructions in the Owner’s Manual will be 10. Any replacement part may be used in the warranted for the period of time before the first performance of any warranty maintenance or 2. The warranty shall commence, on the date of scheduled replacement date for the part. If the part repairs and will be provided without charge to the delivery to the first retail purchaser or from the date fails before the first scheduled replacement, owner. Such usage will not reduce Marine Power’s the engine is first placed in service for demonstra- the part will be repaired or replaced by Marine warranty obligations. tion or any other purpose prior to the sale to the

4 www.MarinePowerUSA.com 1. Introduction 11. Add-on or modified parts, as defined in CCR, 4) and/or Control Module A) Use of an accessories or parts not manufactured Section 1900 (b)(1) and (b)(10), Title 13, that are not 5) Ignition Wires or sold by MARINE POWER. exempted by the Air Resources Board will not D) Lubrication System B) Neglect, failure to follow maintenance be used. The use of any non-exempted add-on or 1) Oil Pump and Internal Parts schedules, accident, abnormal operations, modified parts by the ultimate purchaser will be E) Positive Crankcase Ventilation (PCV) System misuse, negligence, improperly maintained, grounds for disallowing a warranty claim made improperly operated or installed, racing or in accordance with this article statement. Marine 1) PCV 2) Oil Filler Cap engine modification. Problems arising from Power will not be liable under this statement to installation, application, exhaust to engine, fuel warranted failures of warranted parts caused by F) lines to the engine, propping, cooling to the the use of non-exempted add-on or modified part. 1) Exhaust Manifolds and Risers engine or engine damage due to defective 12. The following parts are covered by this general 2) Exhaust electrical hookups. 3) Catalysts emissions warranty statement. C) Rust, corrosion or effects of weather. A) Fuel Metering System G) Miscellaneous Items Used in Above Systems 1) Hoses, Clamps, Fittings, Tubing, Sealing D) Water ingestion through exhaust or 1) Fuel system. 2) Fuel Pressure Regulator or Devices and Mounting Hardware 3) Manifold Absolute Pressure Sensor 2) Pulleys, Belts and Idlers E) Detonation or operation with fuels, oils or 4) Position Sensor 3) Vacuum, Temperature, Check and Timer lubricants which are not suitable for use with 5) Throttle Body Sensitive Valves and Switches this product. Detonation causes: Poor fuel 6) Coolant Temperature Sensor 4) Electronic Controls quality, overloading of engine, improper gear 7) Oxygen Sensors 13. The repair or replacement of any warranted part or propeller selection, engine overheating, 8) Intake Valves otherwise eligible for coverage under this warran- excessive back pressure, incorrect ignition timing, excessive total timing. B) Air Induction System ty may be denied from such warranty coverage if 1) Intake Manifold Marine Power demonstrates that the engine and/ F) Reimbursement for: Haul-out, launch, towing, 2) /Flame Arrestor or part has been abused, neglected, or improper- storage charges, rental charges of any type, ly maintained, and that such abuse, neglect, or inconvenience of any type, loss of time or C) Ignition System improper maintenance was the direct cause of the income, expense of returning a MARINE 1) Spark Plugs need for repair or replacement of the part. POWER product to a service facility, towing, 2) Electronic Ignition System lodging, loss or damage to personal property. 3) Spark Advance/Retard System 14. This Warranty will not apply to:

5 1. Introduction G) replacement and labor is limited to limited warranty. The warranty period applicable to This Special Applications Warranty shall NOT apply to mechanical defects only. Replacement does not Special Applications such as inboard mud boat usage, nor shall it extend to repairs required because of the extend to contaminated fuel, varnish or other shall carry a limited warranty period of one (1) year or following: residues, changes in fuel mixtures, poor octane 150 hours, whichever occurs first. This warranty shall 1. Damages caused by failures or inadequacies in the fuel or adjustments beyond five (5) hours of only cover and be strictly limited to the repair or re- cooling system; engine operation. placement of parts located from the forward. Repair or replacement of drive plates are specifically 2. Damages caused by extreme temperatures in the 15. Marine Power reserves the right to limit exhaust system, including, but not limited to any warranty coverage on engines that have not covered. Any and all transmission warranties must DANGER be handled by the transmission manufacturer directly. occurrences of fire, etc.; accumulated excessive hours through commercial Marine Power’s emission warranty shall not be limit- use or any other non-typical operation. 3. Damages caused by or are the result of any sudden ed by these specific limitations. This warranty covers impact to the propeller or any other part of the en- Special Applications Warranty engine related defective material and/or workmanship gine or its accessories; only, and not replacement or refund of the equipment to Marine Power Engines that are used in inboard mud which the engine may be mounted. 4. Damages or failure of the damper drive plate. boat applicationsW (“SpecialARNING Applications”) carry a strict 2. Safe Boating Monoxide (CO) is found in many areas such as any type of inter- monoxide poisoning on recreational boats, contact the following: nal engines, heaters, charcoal grills, cooking ranges National Marine Manufacturers Association (NMMA) and any other open flame appliances. There are many possible CAUTION 200 East Randolph Drive, Suite 5100, Chicago, IL 60601 variables for the accumulation of carbon monoxide. Wind Carbon Monoxide Exposure 312-946-6200 • www.nmma.org direction, boat speed, vessel proximity to other vessels or structures Carbon Monoxide is a odorless, colorless and tasteless gas are just a few of the possible variables that would permit exposure United States Coast Guard that cannot be smelled, seen or tasted. to carbon monoxide gases. It is important that regular inspections Office of Boating Safety Chicago, IL - CG Headquarters G-OPB-3 Sustained exposure to carbon monoxide gas may lead to of the exhaust system are conducted and maintenance is proper- 2100 Second Street, SW, Washington, DC 20593 brain damage, unconsciousness or death. ly performed by a qualified technician. Adequate air circulation in 202-267-0984 • www.uscgboating.org all areas of your boat are necessary in order to prevent build-up of American Boat & Yacht Council, Inc. (ABYC) Carbon Monoxide is a hazardous gas that is produced when carbon monoxide. Please contact your boat manufacturer if you have 3069 Solomons Island Road, Edgewater, MD 21037-1416 items containing carbon are burned. Items such as, but not questions regarding these hazards. 410-956-1050 • www.abyc.com limited to; wood, coal, gasoline, natural gas, propane or oil. Carbon For more information regarding safe boating practices, and/or carbon

6 www.MarinePowerUSA.com 3. Engine Identification Every Marine Power Engine is equipped with an Engine Identification 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.

Airpac: Cooling water normally supplied by jet drive. Routing of inlet out outlet cooling water lines will affect winteriza- Engines configured for airboat applications. These tion. See Section 9: Winterization procedures. engines use closed cooling systems with automotive style radiators. Their exhaust manifolds are dry and Towpac: usually supplied by the boat builder. Engines configured for watersport tow boat appli- Enpac: cations. Engines may be configured for conventional inboard or v-drive application. In many of these applica- Engines configured for stern drive (I/O) applications. tions throttle and shift is highly integrated with the boat Cooling water supply differs depending on the stern instrumentation drive model mated to. See Section 12: Installation Instructions. Sportpac: Jetpac: Engines configured for traditional inboard vessels. Many of these applications are twin installations. Engines configured for inboard jet drive applications. 7 3. Engine Identification 4.3 GEN V DI 5.3 GEN V DI 6.2 GEN V DI 6.2 LT4 Engine Type V6 V8 V8 V8 Repower X X X X Original Equipment X X X X Unique Feature DIRECT INJECTION DIRECT INJECTION DIRECT INJECTION DI Supercharged Displacement 4.3/262 CID 5.3/327 CID 6.2L/374 CID 6.2L/374 CID & 99.6 x 92 mm 96 x 92 mm 103.25 x 92 mm 103.25 x 92 mm 11 : 1 11: 1 11 : 1 10: 1 Cylinder Block ALUMINUM Aluminum Aluminum Aluminum ALUMINUM Aluminum Aluminum Aluminum Recommended Fuel 87 Octane 87 Octane 91 Octane 93 Octane Max RPM @ Wot 5600 5600 5600 5600 Idle RPM ECM Controlled ECM Controlled ECM Controlled ECM Controlled HP Fuel Pressure 60 PSI 60 PSI 60 PSI 60 PSI LP Fuel Pressure 4-7 PSI 4-7 PSI 4-7 PSI 4-7 PSI Oil Pressure @ 2000 RPM 30-60 PSI 30-60 PSI 30-60 PSI 30-60 PSI Min Oil Pressure @ Idle 10 PSI 10 PSI 10 PSI 10 PSI Operating Temp RW Cooled n/a n/a n/a n/a Operating Temp FW Cooled 175° F 175° F 170-190° F 170-190° F Sparkplug Type 12622441 12622441 12622441 12642722 Sparkplug Gap .075” .075” .075” .075” Timing @ Idle ECM Controlled ECM ECM Controlled ECM ECM Controlled ECM ECM Controlled ECM Timing @ 4000 RPM Controlled Controlled Controlled Controlled 1-8-7-2-6-5-4-3 1-8-7-2-6-5-4-3 1-8-7-2-6-5-4-3 Alternator Rating 95 amps 95 amps 95 amps 95 amps Crankcase Oil DEXOS 1 5W30 GEN 2 DEXOS 1 5W30 GEN 2 DEXOS 5W30 DEXOS 5-30W 1 GEN 2 Oil Capacity Qts. Qts., 8 Qts. 6 8 8 Qts. 5 . Closed Cooling Fluid /Water Antifreeze/Water Antifreeze/Water Antifreeze/Water Closed Cooling Capacity 10 Qts. 10 Qts. 10 Qts. 10 Qts.

8 www.MarinePowerUSA.com 4. Electronic Sequential Fuel Injection Information The engines covered in this manual are equipped with The following sensors constantly provide information to • Barometric Pressure (BARO) Sensor Electronic Fuel Injection. The main fuel Direct the ECM. • Super Charger Inlet Pressure (SCIP) Sensor system components include: • Engine Coolant Temperature (ECT) Sensor • The electric high and low pressure fuel pumps feed • Engine Oil Pressure Sensor • The throttle body assembly • Manifold Absolute Pressure (MAP) Sensor • The fuel injectors • Knock Sensor The fuel injection system is controlled by an Electronic • Positioning (CMP) Sensor Control Module (ECM). The ECM continually monitors information from the various sensors on the engine and • Positioning (CKP) Sensor configures the spark timing and fuel delivery for optimum • Intake Air Temperature (IAT) Sensor (combined performance. Additionally, the ECM protects the engine with the MAP sensor on the LT4) from over-revving and monitors the oil pressure and water temperature. • Throttle Position (TPS) Sensor • Pedal Position (PPS) Sensor • Pre-Catalyst O2 (O2) Sensor (Catalyst equipped engines) • Post-Catalyst O2 (O2) Sensor (Catalyst equipped engines) Engines may include one or more of the following optional sensors. • Engine Oil Temperature Sensor • Feed Fuel Pressure Sensor • Transmission Oil Temperature Sensor • Temperature Sensor

9 5. Engine Alarms and Instrumentation Digital Alarms alarm system. This system is configured to turn on an instrument panel mounted indicator (“MIL” or “Check If, for any reason, one or more of these sensors or Engine”) light, and, optionally, an audible (“buzzer”) associated wiring malfunctions, the ECM’s built in alarm to warn the operator of engine problems. self-diagnostic system sets a trouble code and turns on the Malfunction Indicator Light (MIL) or sounds a buzzer If the “MIL” lights and/or the “buzzer” sounds during to alert the operator of a malfunction. operation, the operator should scan the instrument panel readings for possible sources of trouble. The MIL, buzzer and gauges can signal that something Conditions that may cause alarm activation include: is wrong before it becomes serious enough to cause an expensive repair. Paying attention to the MIL, buzzer and • Low Oil Pressure gauges could also save you or others from injury. The • Engine Overheat (High Temperature) MIL may be replaced by verbiage such as “Service Required” on boats equipped with electronic instrumen- • Electronic Throttle Malfunction tation. • Engine Misfire The MIL or “Service Required” notice comes on when See Section 11: Engine Diagnostics and Codes for more there is a problem with an engine function. Gauges can information. also indicate when there is a problem with an engine If the boat is equipped with CAN-Bus Messaging functions. Often gauges and the MIL (Service Required) (Electronic Instrumentation), the main screen will likely work together to let you know that there is a problem display a “Service Required” message when the ECM with your engine. records an active trouble code. In most cases, when the “MIL” is on, the engine(s) may IMPORTANT: A failure with the Electronic Throttle lose some performance and/or efficiency, but remain will result in idle only operation of the engine. In some running adequately. Also, the light may go out or cases, the throttle may be reset by turning the key off become intermittent, but a trouble code will be logged and then restarting the engine. The operator should for future diagnosis. In any case, the operator must contact his servicing dealer to determine the exact obtain service by an authorized dealer to determine cause of the failure. and repair the exact cause of the malfunction. The engine ECM is programmed to control the engine

10 www.MarinePowerUSA.com 5. Engine Alarms and Instrumentation Instrumentation IMPORTANT: Engines are designed to use Boat builders use many different types of instrumen- both buzzers and MIL lamps. Buzzers are tation in their boats. The operator should understand use to alert operators of severe problems, his instrumentation and note any abnormal operating such as: Low oil pressure, high engine conditions. temperature or low fuel pressure. See Section 11: Engine Diagnostics and Codes for more information.

Analog Instrumentation

Canbus Instrumentation

11 6. SSVEC Fuse and Relay Enclosure

All relays and fuses are located in the Severe Service Vessel Electrical Center (SSVEC). This enclosure is capable of withstanding direct water spray. Additional- ly, it contains a Goretex vent which allows humid vapors to escape without allowing water in.

12 www.MarinePowerUSA.com 6. SSVEC Fuse and Relay Enclosure

Feed Pumps

13 6. SSVEC Fuse and Relay Enclosure

14 www.MarinePowerUSA.com 6. SSVEC Fuse and Relay Enclosure

15 7. Precautions Oil Level Hydrolock the flame arrestor. Check the oil level before each engine start up and Hydrolock describes a condition in which water enters 6. Belt Slinging: Too much water in the bilge of a boat every eight (8) hours of continuous operation. It should the cylinder of an engine. Water is not compressible will sometimes be picked up by the crankshaft be understood that internal combustion engines will and can cause catastrophic damage. Do not try to pulley and carried into the flame arrestor during a use a certain amount of oil during operation as a start an engine that shows sign of having water in the hard acceleration maneuverer. cooling and lubricating agent (especially during break- cylinders. Beware of these situations: To remove water from engine cylinders, take the follow- in period). Oil consumption should decrease after 1. Following Wakes: Sudden slow-downs may cause ing steps: approximately 100 hours of operation. the boat wake to flow over the transom of your 1. Remove all spark plugs. IMPORTANT: The space between the “FULL” and boat. 2. Remove coil wire. “ADD” marks on the dipstick represent one quart. It is 2. Engine Shutdown: Sudden engine shutdown while not necessary to add oil unless the level is at or below the boat is moving may force water into the exhaust 3. engine for 15 seconds. the “ADD” mark. system. 4. If there are any abnormal sounds STOP ENGINE Engine dipstick level may change due to the angle of 3. Improper Installation: Refer to Section 12: Exhaust immediately and contact your MARINE POWER installation. Ensure that “high” oil level is properly Piping. An exhaust system without flappers and the dealer. marked accordingly. specified incline increases the likelihood of water 5. Change engine oil & filters. entering the engine. 6. Replace spark plugs and reattach coil wire. When adding crankcase oil, DO NOT OVERFILL. 4. Improper Hoisting: Operators are sometimes tempt- 7. Start engine. If there are any abnormal sounds ed to reduce hoisting time for propeller changes If crankcase is overfilled, it will cause foaming or aer- STOP ENGINE immediately and contact your by hoisting only the boat stern. Such hoisting can ation of oil in the oil pan. This will effect oil pressure MARINE POWER dealer. which may result in severe internal engine damage. cause residual water in the exhaust system to enter engine cylinders. Water entering engine cylinders will cause the engine to lock because water does not compress. 5. Poor engine cover design: Engines are supposed to be protected from top side water. If the engine hatch (cover) allows water to spill on to the top of the engine, water may enter the cylinders through

16 www.MarinePowerUSA.com 8. Engine Operating Instructions Gasoline Requirements Oil Requirements Place shift lever in the neutral position. Marine Power calibrates their engines EXCEPT LT4 Marine Power recommends the following: If this is the initial start on a new engine turn the ignition (key) switch to the on (run) position (first for use with high quality lead-free gasoline with a Engine Brand/Weight minimum octane rating of 87. Additionally, Marine detent on key switch) and wait for 10 seconds. Turn the 4.3L DEXOS 1 5W-30 GEN 2 Power uses octane scaling calibrations where ignition off and repeat this procedure 2-3 times or until 5. L applicable. Octane scaling enables the engine to 3 DEXOS 1 5W-30 GEN 2 you hear the prime. Then turn the key to the “learn up” if a higher octane fuel (such as 92) is 6.2L DEXOS 1 5W-30 GEN 2 start (crank) position (2nd detent). It is not necessary purchased. There is a noticeable performance LT4 DEXOS 1 5-30W GEN 2 to hold the key switch in this position as the Marine difference with higher octane fuels. If the boat is Marine Power recommends that the engine oil be Power “SMART START” will take over. If the fuel pump is primed the engine should start within 3-5 seconds. used in heavily loaded conditions (i.e. heavily changed every 100 hours of engine operation, but no ballasted to produce large wakes for surfing or less frequently than once each calendar year, and After the engine starts, idle speed (RPM) will be wakeboarding) Marine Power recommends the use of that the engine be replaced every time the controlled by the ECM. The idle RPM will be elevated premium fuel (93 octane minimum). SEE LT4 engine oil is changed. following a cold start until the engine warms to its WARNING. normal operating temperature. Starting Engine EFI The use of gasoline containing ethanol is very DANGER Check for water flowing through the engine cooling prevalent. Marine Power engines are calibrated to DO NOT operate engine without water being system. Water should mix with the engine exhaust. In operate on fuel containing up to 10% ethanol (E10). Do supplied to raw water pump as pump impeller all cases, your positive indicator is exhaust water flow. not use fuel with ethanol content higher than 10% (E10). and engine will be damaged. Check the boat’s instrument panel for any service Ethanol blended fuel acts as a solvent and will absorb warnings or alarms. moisture. Excessive moisture can cause lean conditions, Check operation of throttle and shift controls. vapor lock and shortened fuel life. The solvent charac- WARNING teristic can cause gum, sludge and other particles to be Gasoline vapors are highly explosive under certain Check fill level before leaving the trailer or loosened up and carried through the fuel system. conditions. dock. Marine Power recommends the use of fuel Operate the bilge blower for five (5) minutes. If not Engine Break-In/25 Hour Inspection equipped with a bilge blower, open engine hatch and stabiliz-er such as Sta-Bil. Fuel stabilizer is To insure the maximum life of your Marine Power leave open before starting the engine to remove any recommended for winter storage and should also be CAUTION Engine, the following engine break-in guidelines are explosive vapors from the engine compartment. used if you expect to use less than a full tank of fuel recommended. over a 2-3 week period of time. Follow the label instructions whenever adding fuel stabilizer to the fuel 17 tank. 8. Engine Operating Instructions Marine Power considers the first ten (10) hours of engine operation to be the break-in period. During this break-in period: Do not operate the engine at wide-open throttle. Do not operate the boat at or near the maximum capacity specified on the USCG label. Limit the maximum engine speed to 3500 RPM Avoid running the engine at a constant/steady RPM for sustained periods of time. (i.e. vary the throttle/engine speed frequently) Check the engine oil level at the beginning of each boating day, and after each 2-3 hours of engine operation. Any time oil level is checked look for milky discoloration, if found consult with your dealer. After the first ten (10) hours of engine operation but before twenty-five (25) hours return the boat to your dealer for its first engine oil and filter change and initial engine inspection.

WARNING: The LT4 Is a Premium 93 Octane REQUIRED engine. The engine will operate at significantly reduced power output with octane levels down to 90. Operating the LT4 on fuel below 90 Octane can result in engine damage and or failure! Such warranty will not be covered under warranty!

18 www.MarinePowerUSA.com 9. 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. If your engine is attached to a v-drive transmission, pay particular attention to the draining of the v-drive cooler. Remove end caps on heat exchanger. Inspect for debris and trapped water. Remove zinc anode and replace if necessary. Spray each of your engine mounts with WD-40 or equivalent.

20 www.MarinePowerUSA.com

9. Winterization Full Closed Inboard Jet Engines Test antifreeze-water concentration to assure adequate 6.2 JETPAC protection for your location. These engines are designed to be self-draining, however, it is recommended that the heat exchang- For best results er ends be inspected for debris and trapped water use a Vacuum frequently. Cooling System Filler when refilling or bleeding engine coolant.

23 10. Engine Maintenance Scheduled Maintenance By Owner Service Engine After Every 50 Every 100 Startup 10 Hours of Hours of Hours of Each Day Operation Operation Operation Check Engine Oil Level * 3 3 Inspect Fuel Lines and Connections for Leaks 3 3 Check Coolant Level in Tank (If Equipped with Closed Cooling) 3 3 Inspect and Clean Sea Strainer (If Equipped) 3 3 Inspect Entire Power Package for Leaks (Water, Fuel, Oil, Exhaust, etc.) 3 3 Inspect Belts for Tension and Wear 3 3 Inspect Battery (Terminals and Fluid Levels) 3 3 Check Battery Connection to Engine 3 3 Touch Up Exterior Surface with Marine Power Paint 3 3 Inspect Zinc Anodes in Heat Exchanger for Deterioration (If Equipped with Closed Cooling) 3 3 Check Power Steering Fluid (If Equipped) X Check Transmission Fluid Level 3 3 Lubricate Pinion and Shaft 3 * Engine Start-Up Each Day and Once Every Eight (8) Hours of Operation.

24 www.MarinePowerUSA.com 10. 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 3 3 3 Change Filter on Fuel/Water Separator 3 3 Check Engine Mounts (Tightness) 3 3 Check Riser and Manifold Bolts for Tightness 3 3 3 Check for Loose, Damaged or Missing Engine Parts 3 Check Wire Harness Plugs for Corrosion and Connections 3

Check Condition of Spark Plugs (Replace if Necessary) 3 Inspect Hoses for Deterioration 3 Replace Impeller in Seawater Pump 3 Check Propeller and Shaft Alignment 3

Clean and Inspect Flame Arrestor and Crank Case Vent Hose 3 3

Change Transmission Fluid 3 Change Coolant (If Equipped with Closed Cooling) 3 Clean Sea Water Section of Heat Exchanger 3

25 10. Engine Maintenance This manual provides basic information on routine Electrical, ignition and fuel system components on Crankcase Oil Change maintenance of Marine Power Engines. Whether the Marine Power Engines comply with U.S. Coast Guard IMPORTANT! Start engine and operate until normal reader is an experienced marine mechanic or a first (USCG) Rules and Regulations to minimize risks of temperature is reached. Warm oil flows more freely time boat owner, we strongly suggest you thorough- fire and explosion. Use of replacement electrical, carrying away more impurities. Remove the oil into a ly read these procedures BEFORE you attempt any ignition and fuel components which do not comply suitable container. Marine Power equips their engines procedure. Make sure you are familiar with the tools with these rules and regulations could result in a fire with an E-Z oil drain hose. This hose can sometimes be suggested and the methods recommended. Safety or explosion and must be avoided. The electrical and routed through the hull drain fitting while the boat is on is our first concern. If repair required is beyond your ignition system is capable of violent electrical its trailer. Draining can take several hours if the oil is expertise, please contact your dealer or other qualified shock. Always disconnect the battery cables when DANGER not warmed before draining. Some oil will remain in the technician. This manual contains guidelines to convey a performing any work where the cables could touch. pan and engine. It is a small quantity but may make the particular level of risk: Take care to properly install and tighten all components new oil appear used. when servicing the electrical, ignition and fuel systems. DANGER If the installation is not correct, sparks could ignite fuel DANGER vapors from the fuel system. WARNING Hazards that will result in severe injury or death. If you are doing repair work around the intake or The Federal Water Pollution Control Act prohibits exhaust openings, always protect those openings the discharge of oil or oily waste into or upon the against foreign matter entering the cylinders. Care navigable waters and contiguous zone of the WARNING must be taken to use exact replacement parts. United States, if such discharge causes a film upon, Hazards thatW couldARNING result in severe injury or death. Damage could result if mismatched. If a grade 5 hex or discolorationCA of, theUT surface IONof the water, or Caution: Hazards which could result in minor injury head bolt is removed, the same grade 5, hex head bolt causes an emulsion or sludge beneath the surface or property damage. must be replaced. If you cannot re-use the same bolt, do of the water. Violators are subject to a penalty of $5,000.00. Please be careful. not improvise. Performance could be sacrificed CAUTION without original Marine Power parts or parts After replacing drained oil, start engine and run for CAUTION recommended by Marine Power. A marine environment 5 minutes to circulate oil throughout. Inspect entire is a tough one. Parts subjected to salt water can rapidly engine for leakage. Shut off engine and wait 5 minutes corrode and engine failure could result. Warranty on for oil to drain back into pan. Check level with dipstick. Marine Power Engines could also be affected if other Add oil to proper level if needed. than recommended replacement parts are used.

26 www.MarinePowerUSA.com DANGER

WARNING 10. Engine Maintenance Start engine. Turn on water. Run for approximately 5 CAUTION minutes and inspect for leaks. DO NOT overfill crankcase with oil. Agitation or Check to see that oil shows “FULL” on dipstick. splashing of oil may cause it to become aerat- Start engine. Run for approximately 5 minutes and ed, which will affect oil pressure and may result inspect for leaks. internal engine damage from lack of lubrication. Oil Shut off engine and wait 5 minutes for oil to drain back being splashed by parts onto into pan. Check level with dipstick. Add oil to proper the walls of the cylinder in greater quantity than the level if needed. rings can control will subsequently be drawn into the and burned. Continuous ALWAYS CONTACT YOUR NEAREST MARINE operation under these conditions can cause carbon POWER SERVICING DEALER IF YOU HAVE A to form on chamber surfaces, which will adversely PROBLEM. affect engine performance and may lead to prema- ture engine repair. Oil Filters NOTE: Lay a towel or catch basin under the filter(s) to catch any spilled oil. Unscrew old filter by using an oil filter wrench and turn counter clockwise. Once removed, clean mounting base. Be sure old is removed from mounting base. Apply thin film of oil (do not use grease) to filter gasket. Be sure gasket is seated properly in base of oil filter. Hand tighten filter, plus ½ turn, after gasket contacts mounting base. Use a filter wrench is necessary. Do not over tighten. Check to see that oil shows “FULL” on dipstick.

27 10. Engine Maintenance Not used on LT4 Flame Arrestor Clean the flame arrestor regularly. Fuel Flow Schematic High Pressure 1. Remove fastener from flame arrestor. FeedPump Low Pressure Feed Pump is 4-7 PSI at 2. Clean with a suitable solvent and blow dry. outlet. Inlet has a small screen inside Outlet (60 PSI) 3. Reverse steps to assemble. fitting. This screen may be flushed by reversing polarity on electrical G-Force Fuel System connectors and operating pump in 1. Position catch basin under filter. reverse. High pressure Feed pump must be unplugged during this 2. Remove cooling cover. procedure. 3. Unscrew canister bowl. Low Pressure 4. Pull element down from pump. Feed Pump 5. Push new element (Part #396007) on pump until click is felt. IN OUT 6. Replace O-ring (included with filter). 7. Re-install canister bowl on unit - snug tight only. 8. Two 10-second key ups should prime system.

Negative Positive Terminal Terminal

28 www.MarinePowerUSA.com DANGER 10. Engine Maintenance Battery Cables Serpentine belt system maintains tension with a spring-loaded tensioner. Normally, no maintenance WARNING In multi-EFI power packages, each engine must be is required. Do not recharge a weak battery in a boat. Remove connected to its own battery. This provides the and recharge in a ventilated area away from fuel required voltage source for the ECM. In these Sea Water Pump Impeller Replacement applications where battery switches are used, it is vapors, sparks or fames. Electrical systems in a Remove 4 screws from pump cover. marine environment require periodic attention. important that each switch be positioned to allow each Continued useCA of a weakUT batteryION or dirty terminals engine to run off its own individual battery. DO NOT Remove cover and gasket. can cause solenoid or starter problems. Clean battery run engines with the battery switches in “BOTH” or Pry out impeller using a flat screw driver on each side and terminals every 100 hours. Note the condition “ALL” positions. This will allow the other engine’s of the center of the shaft. of your battery cables. When reconnecting battery battery to be used in case of emergency to start the cables make sure that the RED cable is on the (+) engine with the dead battery. Install new impeller. terminal and the BLACK cable is on the (-) terminal. Replace gasket, cover and re-tighten screws. Black is ground. Alternator BeltDANGER Tension

WARNING Exploded View of Sea Water Pump DO NOT RUN AC WIRING ADJACENT TO DC WIRING WARNING Multiple Engine Make sure ignition key is removed and engine is not running before inspecting belts. Battery Precautions - EFI

CAUTION

29 10. Engine Maintenance Closed Cooling System Surge Tank: Some models are equipped with a surge After initial fill, start engine and continue filling tank rather than a recovery bottle. The surge tank heat exchanger. Engine must be purged of air by The closed cooling system is designed to provide replaces the heat exchanger filler neck and pressure bleeding system. extended life to your new Marine Power Engine. Your cap and is pressure capable whereas the recovery engine will operate at a different temperature range 4.3/5.3/6.2L Horizontal Heat Exchanger Full bottle is not. Maintain the appropriate level in the from a raw water cooled engine. Please refer to the Systems: These engines maybe difficult to purge surge tank at all times. If coolant is consistently low, appropriate Engine Identification on Page 15 for without a vacuum assembly. If such an assembly is additional inspection for leaks in the cooling system proper cooling ranges. The cooling system does not available, operator should continue to leave may be required. require certain preventative maintenance to keep it in surge tank cap off and force coolant into bottle until optimum operating conditions. Filler Neck and Pressure Cap: DO NOT remove is open and all air purged. Once pressure cap when engine is HOT. If coolant is low, add thermostat is open and engine temperature is stable, Heat Exchanger: All closed cooled engines the proper mixture (50% water/50% antifreeze) to the reinstall surge tank cap. incorporate a shell and tube heat exchanger. This unit top of the filler neck located on the heat exchanger tank. exchanges heat between the sea water and the engine If coolant is consistentlyDANGER low, additional inspection for coolant. These units require very little maintenance. leaks in the cooling system may be required. A routine inspection of the interior tube sheets during winterization is sufficient. Be sure to remove any debris Filling Closed Cooling System found during this inspection. Zinc Anode: Your heat exchanger is equipped with a zinc anode that is approximately 2” long. If your engine WARNING is operated and maintained in saltwater this anode Do not remove pressure cap when engine is hot. should be inspected for deterioration after the first Coolant is under pressure and may be forced out 10 hours of operation. Inspect again after 50 hours of causing personal injury. After engine is cooled, operation and every 50 hours thereafter. remove cap slowly to allow pressure to escape. Recovery Bottle: The plastic recovery bottle is IMPORTANT! CAThe closedUT coolingION system must attached to the heat exchanger tank (on most models) remain filled year-round with the proper mixture of 50% and fills with coolant during operation when the internal antifreeze/50% water to assure protection of system water temperature is higher. If necessary, add coolant during the lowest exposed temperatures. Insure that only when engine is cold. all drain plugs are installed and tightened. Fill heat exchanger (tank) with 50/50 antifreeze/water mixture. 30 www.MarinePowerUSA.com MEFI 7 ENGINE DIAGNOSTIC CODES

DESCRIPTION CODE # FMI

DTC_SPN_BaroSensor 108 DTC_FMI_BaroSensorCorrelation 2 DTC_FMI_BaroSensorHigh 3 DTC_FMI_BaroSensorLow 4 DTC_FMI_BaroSensorStability 10

DTC_SPN_BoostBypass 66034 DTC_FMI_BoostBypassIneffective 7 DTC_FMI_BoostBypassShortHigh 3 DTC_FMI_BoostBypassShortLowOrOpen 5

DTC_SPN_BoostControl 66035 DTC_FMI_BoostControlExceedLimit 0 DTC_FMI_BoostControlAccuracy 7 DTC_FMI_BoostControlShortHigh 3 DTC_FMI_BoostControlShortLowOrOpen 5

DTC_SPN_BuzzerDriver 66007 DTC_FMI_BuzzerDriverShortHigh 3 DTC_FMI_BuzzerDriverShortLowOrOpen 5

DTC_SPN_CalMemory 630 DTC_FMI_CalMemoryFailure 13 DTC_FMI_CalNotCompatibleWithGmCal 12 DTC_FMI_CalNotCompatibleWithHost 14

DTC_SPN_CamPhaserW 65570 DTC_FMI_CamPhaserAccuracy 7 DTC_FMI_CamPhaserRefAngle 2 DTC_FMI_CamPhaserShortHighOrOpen 5 DTC_FMI_CamPhaserShortLow 4

DTC_SPN_CamPhaserX 65571 DTC_FMI_CamPhaserAccuracy 7 DTC_FMI_CamPhaserRefAngle 2 DTC_FMI_CamPhaserShortHighOrOpen 5 DTC_FMI_CamPhaserShortLow 4

DTC_SPN_CamPhaserY 65572 DTC_FMI_CamPhaserAccuracy 7 DTC_FMI_CamPhaserRefAngle 2 DTC_FMI_CamPhaserShortHighOrOpen 5 DTC_FMI_CamPhaserShortLow 4

DTC_SPN_CamPhaserZ 65573 DTC_FMI_CamPhaserAccuracy 7 DTC_FMI_CamPhaserRefAngle 2 DTC_FMI_CamPhaserShortHighOrOpen 5 DTC_FMI_CamPhaserShortLow 4

DTC_SPN_CamSensorW 65723 DTC_FMI_CamAngleOutOfRange 7 DTC_FMI_CamSyncFault 2 DTC_FMI_CamSignalMissing 8

DTC_SPN_CamSensorX 65724 DTC_FMI_CamAngleOutOfRange 7 DTC_FMI_CamSyncFault 2 DTC_FMI_CamSignalMissing 8

DTC_SPN_CamSensorY 65725 DTC_FMI_CamAngleOutOfRange 7 DTC_FMI_CamSyncFault 2 DTC_FMI_CamSignalMissing 8

DTC_SPN_CamSensorZ 65726 DTC_FMI_CamAngleOutOfRange 7 DTC_FMI_CamSyncFault 2 DTC_FMI_CamSignalMissing 8

DTC_SPN_CanBusGovCmd 65560 DTC_FMI_CanBusGovCmdLost 9

DTC_SPN_Can1BusHardware 65559 DTC_FMI_CanBusHardwareFault 11

DTC_SPN_Can2BusHardware 65558 DTC_FMI_CanBusHardwareFault 11

DTC_SPN_CanBusStblCntrlMsg 65557 DTC_FMI_CanBusStblCntrlMsgLost 9

DTC_SPN_Cat_A_Efficiency 65675 DTC_FMI_CatFailure 11

DTC_SPN_Cat_B_Efficiency 65676 DTC_FMI_CatFailure 11

DTC_SPN_ChangeOilNow 65555 DTC_FMI_ChangeOilNow 1

DTC_SPN_ChangeOilSoon 65555 DTC_FMI_ChangeOilSoon 18

DTC_SPN_CoolantTempSensor 110 DTC_FMI_CoolantTempSensorHigh 3 DTC_FMI_CoolantTempSensorLow 4

DTC_SPN_CoolantTempWarn 110 DTC_FMI_CoolantTempHighWarn 15

DTC_SPN_CoolantTempWarnExtreme 110 DTC_FMI_CoolantTempExtremeHighWarn 16 DTC_SPN_Cpu 65580 DTC_FMI_CpuFailure 12

DTC_SPN_CrankSensor 636 DTC_FMI_ExcessiveCrankReSync 2 DTC_FMI_CrankSyncFault 8

DTC_SPN_DevModeCal 65730 DTC_FMI_DevModeCal 13

DTC_SPN_DtcLamp1 66008 DTC_FMI_DtcLamp1ShortHigh 3 DTC_FMI_DtcLamp1ShortLowOrOpen 5

DTC_SPN_DtcLamp2 66009 DTC_FMI_DtcLamp2ShortHigh 3 DTC_FMI_DtcLamp2ShortLowOrOpen 5

DTC_SPN_DtcLamp3 66006 DTC_FMI_DtcLamp3ShortHigh 3 DTC_FMI_DtcLamp3ShortLowOrOpen 5

DTC_SPN_Egr 66016 DTC_FMI_EgrAccuracy 7 DTC_FMI_EgrShortHighOrOpen 5 DTC_FMI_EgrShortLow 4

DTC_SPN_EmergencyStopWarn 65710 DTC_FMI_EmergencyStopWarn 31

DTC_SPN_Est1 65541 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_Est2 65542 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_Est3 65543 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_Est4 65544 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_Est5 65545 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_Est6 65546 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_Est7 65547 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_Est8 65548 DTC_FMI_EstShortHighOrOpen 5 DTC_FMI_EstShortLow 4

DTC_SPN_EtcActuation 65615 DTC_FMI_EtcActuationFault 7

DTC_SPN_EtcPps1 65605 DTC_FMI_EtcPps1DataRx 12 DTC_FMI_EtcPps1VoltageHigh 3 DTC_FMI_EtcPps1VoltageLow 4

DTC_SPN_EtcPps12Correlation 65613 DTC_FMI_EtcPps12CorrelationFault 2

DTC_SPN_EtcPps2 65604 DTC_FMI_EtcPps2DataRx 12 DTC_FMI_EtcPps2VoltageHigh 3 DTC_FMI_EtcPps2VoltageLow 4

DTC_SPN_EtcReturn 65618 DTC_FMI_EtcReturnFault 7

DTC_SPN_EtcTpsSentMsg 65600 DTC_FMI_EtcTpsSentMsgFault 12

DTC_SPN_EtcTps1 65602 DTC_FMI_EtcTps1VoltageHigh 3 DTC_FMI_EtcTps1VoltageLow 4

DTC_SPN_EtcTps12Correlation 65610 DTC_FMI_EtcTps12CorrelationFault 2

DTC_SPN_EtcTps2 65601 DTC_FMI_EtcTps2VoltageHigh 3 DTC_FMI_EtcTps2VoltageLow 4

DTC_SPN_FeedFuelPressSensor 94 DTC_FMI_FeedFuelPressSensorHigh 3 DTC_FMI_FeedFuelPressSensorLow 4

DTC_SPN_FeedFuelPressError 94 DTC_FMI_FeedFuelPressHighError 15 DTC_FMI_FeedFuelPressLowError 17

DTC_SPN_FeedFuelPump1Relay 66017 DTC_FMI_FeedFuelPump1RelayShortHighOrOpen 5 DTC_FMI_FeedFuelPump1RelayShortLow 4

DTC_SPN_FeedFuelPump2Relay 66025 DTC_FMI_FeedFuelPump2RelayShortHighOrOpen 5 DTC_FMI_FeedFuelPump2RelayShortLow 4

DTC_SPN_FuelLevelSensor1 96 DTC_FMI_FuelLevelSensorHigh 3 DTC_FMI_FuelLevelSensorLow 4

DTC_SPN_FuelLevelSensor2 38 DTC_FMI_FuelLevelSensorHigh 3 DTC_FMI_FuelLevelSensorLow 4

DTC_SPN_FuelRailPressDiagSensor 1349 DTC_FMI_FuelRailPressDiagSensorHigh 3 DTC_FMI_FuelRailPressDiagSensorLow 4

DTC_SPN_FuelRailPressSensor 157 DTC_FMI_FuelRailPressSensorCorrelation 2 DTC_FMI_FuelRailPressSensorHigh 3 DTC_FMI_FuelRailPressSensorLow 4

DTC_SPN_FuelRailSentMsg 66032 DTC_FMI_FuelRailSentShortHigh 3 DTC_FMI_FuelRailSentShortLow 4 DTC_FMI_FuelRailSentPressAge 9 DTC_FMI_FuelRailSentTempAge 10

DTC_SPN_FuelTempSensor 174 DTC_FMI_FuelTempSensorCorrelationFault 2 DTC_FMI_FuelTempSensorResistanceHigh 3 DTC_FMI_FuelTempSensorResistanceLow 4 DTC_FMI_FuelTempSensorSkewedHigh 0 DTC_FMI_FuelTempSensorSkewedLow 1

DTC_SPN_GeneralWarn1 65701 DTC_FMI_GeneralWarn1 31 DTC_FMI_GeneralWarn1RollOverActive 31 DTC_FMI_GeneralWarn1RollOverOutOfRangeLow 4

DTC_SPN_GeneralWarn2 65702 DTC_FMI_GeneralWarn2 31

DTC_SPN_GeneralWarn3 65703 DTC_FMI_GeneralWarn3 31

DTC_SPN_GovStatusLamp 66005 DTC_FMI_GovStatusLampShortHigh 3 DTC_FMI_GovStatusLampShortLowOrOpen 5

DTC_SPN_HpfpPressError 66031 DTC_FMI_HpfpPressErrorHigh 15 DTC_FMI_HpfpPressErrorLow 17

DTC_SPN_HpfpSolenoid 66029 DTC_FMI_HpfpSolenoidCurrentHigh 6 DTC_FMI_HpfpSolenoidShortedHighOrOpenOrCurrentLow 5 DTC_FMI_HpfpSolenoidShortedLow 4

DTC_SPN_HpfpSolenoidEnbl 66028 DTC_FMI_HpfpSolenoidEnblShortedHigh 3 DTC_FMI_HpfpSolenoidEnblShortedLowOrOpen 5

DTC_SPN_Inj1 66051 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_Inj2 66052 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_Inj3 66053 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_Inj4 66054 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_Inj5 66055 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_Inj6 66056 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_Inj7 66057 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_Inj8 66058 DTC_FMI_InjShortHighOrOpen 5 DTC_FMI_InjShortLow 4

DTC_SPN_InjEnbl1 651 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5

DTC_SPN_InjEnbl2 652 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5

DTC_SPN_InjEnbl3 653 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5

DTC_SPN_InjEnbl4 654 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5 DTC_SPN_InjEnbl5 655 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5

DTC_SPN_InjEnbl6 656 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5

DTC_SPN_InjEnbl7 657 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5

DTC_SPN_InjEnbl8 658 DTC_FMI_InjEnblShortHigh 3 DTC_FMI_InjEnblShortLowOrOpen 5

DTC_SPN_InterCoolerRelay 66030 DTC_FMI_InterCoolerRelayShortHigh 3 DTC_FMI_InterCoolerRelayShortLowOrOpen 5

DTC_SPN_KnockExcessive 65550 DTC_FMI_KnockExcessive_LowOctane 16

DTC_SPN_KnockSensor1 65551 DTC_FMI_KnockSensorInactive 1 DTC_FMI_KnockSensorOpen 5 DTC_FMI_KnockSensorShortHigh 3 DTC_FMI_KnockSensorShortLow 4

DTC_SPN_KnockSensor2 65552 DTC_FMI_KnockSensorInactive 1 DTC_FMI_KnockSensorOpen 5 DTC_FMI_KnockSensorShortHigh 3 DTC_FMI_KnockSensorShortLow 4

DTC_SPN_MapSensor 106 DTC_FMI_MapSensorCorrelation 2 DTC_FMI_MapSensorHigh 3 DTC_FMI_MapSensorLow 4 DTC_FMI_MapSensorSkewedHigh 0 DTC_FMI_MapSensorSkewedLow 1

DTC_SPN_MatSensor 105 DTC_FMI_MatSensorHigh 3 DTC_FMI_MatSensorLow 4

DTC_SPN_MatWarn 105 DTC_FMI_MatHighWarn 15

DTC_SPN_Mhc 65581 DTC_FMI_MhcFailure 12

DTC_SPN_MilDriver 66003 DTC_FMI_MilDriverShortHigh 3 DTC_FMI_MilDriverShortLowOrOpen 5

DTC_SPN_Misfire 65590 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl1 65591 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl2 65592 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl3 65593 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl4 65594 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl5 65595 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl6 65596 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl7 65597 DTC_FMI_Misfire 7

DTC_SPN_MisfireCyl8 65598 DTC_FMI_Misfire 7

DTC_SPN_MisfireRandom 65599 DTC_FMI_Misfire 7

DTC_SPN_NonEtcTps 51 DTC_FMI_NonEtcTpsHigh 3 DTC_FMI_NonEtcTpsLow 4 DTC_FMI_NonEtcTpsSkewedHigh 0

DTC_SPN_NvRam 65582 DTC_FMI_NvRamFailure 2

DTC_SPN_OemOutput1 66040 DTC_FMI_OemOutput1ShortHigh 3 DTC_FMI_OemOutput1ShortLowOrOpen 5

DTC_SPN_OemOutput2 66041 DTC_FMI_OemOutput2ShortHigh 3 DTC_FMI_OemOutput2ShortLowOrOpen 5

DTC_SPN_OemOutput3 66042 DTC_FMI_OemOutput3ShortHigh 3 DTC_FMI_OemOutput3ShortLowOrOpen 5

DTC_SPN_OemOutput4 66043 DTC_FMI_OemOutput4ShortHigh 3 DTC_FMI_OemOutput4ShortLowOrOpen 5

DTC_SPN_OemSignalLamp_LF 66060 DTC_FMI_OemSignalLampShortHigh 3 DTC_FMI_OemSignalLampShortLowOrOpen 5

DTC_SPN_OemSignalLamp_RF 66061 DTC_FMI_OemSignalLampShortHigh 3 DTC_FMI_OemSignalLampShortLowOrOpen 5

DTC_SPN_OemSignalLamp_LR 66062 DTC_FMI_OemSignalLampShortHigh 3 DTC_FMI_OemSignalLampShortLowOrOpen 5

DTC_SPN_OemSignalLamp_RR 66063 DTC_FMI_OemSignalLampShortHigh 3 DTC_FMI_OemSignalLampShortLowOrOpen 5

DTC_SPN_OilLevelWarn 98 DTC_FMI_OilLevelLowWarn 17

DTC_SPN_OilPressSensor 100 DTC_FMI_OilPressSensorHigh 3 DTC_FMI_OilPressSensorLow 4 DTC_FMI_DiscreteOilPressSensorInactive 11

DTC_SPN_OilPressWarn 100 DTC_FMI_OilPressLowWarn 17

DTC_SPN_OilTempSensor 175 DTC_FMI_OilTempSensorHigh 3 DTC_FMI_OilTempSensorLow 4

DTC_SPN_OilTempWarn 175 DTC_FMI_OilTempHighWarn 15

DTC_SPN_OxyFuelTrim_A 65565 DTC_FMI_OxyFuelTrimHigh 0 DTC_FMI_OxyFuelTrimLow 1

DTC_SPN_OxyFuelTrim_B 65566 DTC_FMI_OxyFuelTrimHigh 0 DTC_FMI_OxyFuelTrimLow 1

DTC_SPN_OxyHeater_A1 66019 DTC_FMI_OxyHeaterShortHigh 3 DTC_FMI_OxyHeaterShortLowOrOpen 5 DTC_FMI_OxyHeaterDutyCycleHigh 8

DTC_SPN_OxyHeater_A2 66021 DTC_FMI_OxyHeaterShortHigh 3 DTC_FMI_OxyHeaterShortLowOrOpen 5 DTC_FMI_OxyHeaterDutyCycleHigh 8

DTC_SPN_OxyHeater_B1 66020 DTC_FMI_OxyHeaterShortHigh 3 DTC_FMI_OxyHeaterShortLowOrOpen 5 DTC_FMI_OxyHeaterDutyCycleHigh 8

DTC_SPN_OxyHeater_B2 66022 DTC_FMI_OxyHeaterShortHigh 3 DTC_FMI_OxyHeaterShortLowOrOpen 5 DTC_FMI_OxyHeaterDutyCycleHigh 8

DTC_SPN_OxyResponse_A1 65567 DTC_FMI_OxyResponseInsufficientSwitching 8 DTC_FMI_OxyResponseSlow 10

DTC_SPN_OxyResponse_B1 65568 DTC_FMI_OxyResponseInsufficientSwitching 8 DTC_FMI_OxyResponseSlow 10

DTC_SPN_OxyVoltage_A1 65561 DTC_FMI_OxyVoltageOpen 5 DTC_FMI_OxyVoltageLow 4 DTC_FMI_OxyVoltagePeLow 1 DTC_FMI_OxyVoltageHigh 3 DTC_FMI_OxyVoltageDeHigh 0

DTC_SPN_OxyVoltage_A2 65562 DTC_FMI_OxyVoltageOpen 5 DTC_FMI_OxyVoltageLow 4 DTC_FMI_OxyVoltagePeLow 1 DTC_FMI_OxyVoltageHigh 3 DTC_FMI_OxyVoltageDeHigh 0

DTC_SPN_OxyVoltage_B1 65563 DTC_FMI_OxyVoltageOpen 5 DTC_FMI_OxyVoltageLow 4 DTC_FMI_OxyVoltagePeLow 1 DTC_FMI_OxyVoltageHigh 3 DTC_FMI_OxyVoltageDeHigh 0

DTC_SPN_OxyVoltage_B2 65564 DTC_FMI_OxyVoltageOpen 5 DTC_FMI_OxyVoltageLow 4 DTC_FMI_OxyVoltagePeLow 1 DTC_FMI_OxyVoltageHigh 3 DTC_FMI_OxyVoltageDeHigh 0

DTC_SPN_PowertrainRelayContact 66014 DTC_FMI_PowertrainRelayContactLow 4

DTC_SPN_PowertrainRelayDriver 66013 DTC_FMI_PowertrainRelayDriverShortHigh 3 DTC_FMI_PowertrainRelayDriverShortLowOrOpen 5

DTC_SPN_ScipSensor 3563 DTC_FMI_ScipSensorCorrelation 2 DTC_FMI_ScipSensorHigh 3 DTC_FMI_ScipSensorLow 4 DTC_FMI_ScipSensorSkewedHigh 0 DTC_FMI_ScipSensorSkewedLow 1

DTC_SPN_ShiftInterrupt 66026 DTC_FMI_ShiftInterruptFault 7

DTC_SPN_SlowModeLamp 66010 DTC_FMI_SlowModeLampShortHigh 3 DTC_FMI_SlowModeLampShortLowOrOpen 5

DTC_SPN_SpeedBasedOutput 66011 DTC_FMI_SpeedBasedOutputShortHigh 3 DTC_FMI_SpeedBasedOutputShortLowOrOpen 5

DTC_SPN_SpeedSensor 84 DTC_FMI_SpeedSensorAnalogHigh 3 DTC_FMI_SpeedSensorAnalogLow 4 DTC_FMI_SpeedSensorCanMsgLost 12 DTC_FMI_SpeedSensorErratic 2 DTC_FMI_SpeedSensorSkewedLow 1

DTC_SPN_StarterRelayDriver 66002 DTC_FMI_StarterRelayDriverShortHighOrOpen 5 DTC_FMI_StarterRelayDriverShortLow 4

DTC_SPN_SvsLamp 66004 DTC_FMI_SvsLampShortHigh 3 DTC_FMI_SvsLampShortLowOrOpen 5

DTC_SPN_SystemVoltageWarn 627 DTC_FMI_SystemVoltageHighWarn 15 DTC_FMI_SystemVoltageLowWarn 17

DTC_SPN_Tachometer 66018 DTC_FMI_TachometerShortHigh 3 DTC_FMI_TachometerShortLowOrOpen 5

DTC_SPN_TiapSensor 3562 DTC_FMI_TiapSensorCorrelation 2 DTC_FMI_TiapSensorHigh 3 DTC_FMI_TiapSensorLow 4 DTC_FMI_TiapSensorSkewedHigh 0 DTC_FMI_TiapSensorSkewedLow 1

DTC_SPN_V5Buff_A 65620 DTC_FMI_V5BuffLow 4

DTC_SPN_V5Buff_B 65621 DTC_FMI_V5BuffLow 4 DTC_SPN_V5Buff_C 65622 DTC_FMI_V5BuffLow 4

DTC_SPN_V5Buff_D 65623 DTC_FMI_V5BuffLow 4

DTC_SPN_VarGov 65690 DTC_FMI_VarGovHigh 3 DTC_FMI_VarGovLow 4 START SEQUENCE-1 MEFI 7

• Turn Battery Switch on (if boat equipped) “Bussmann” 2-way Connector #5

5C Energized with C A 12 Volts with Battery Switch on (Power enters Bussman)

A. Engine Ground B. Not used C. B+ from Starter post

Connector viewed as connected to the Bussmann (Wire side view) START SEQUENCE-2

• Turn Key to Ignition Position IGNITION POWER ON

• 12 Volts @ 2C Enables Run/Crank Relay (R2) • Run/Crank Relay then energizes 2E which supplies 12 Volts to ECM J1-51 • ECM “Wakes Up” • ECM then Provides 12 Volts To Bussman 1E and 1F which energizes Fuel Feed Pump Relays • Fuel Feed Pump Relays provide 12V to 1C and 1G which turns on Feed Fuel Pumps for Initial Prime. Listen for Pumps running. “Bussmann” Connector #2 (Grey)

D C B A (1). Ignition on Enables Run/ (2). 2E Supplies Crank Relay 12 Volts to (R2) ECM J1-51 E F G H ECM "Wakes Up"

A. Ignition+ to Fuel Injectors E. Run/Crank Relay to J1-51 B. B+ F. 12V+ to Pump C. Ignition+ from Helm G. Ignition+ to Ignition Coils D. Intercooler Pump Relay Control J1-49 H. Ignition+ to O2 Sensor Heater “Bussmann” Connector #1 (Black)

D C B A (4). Fuel Pump Relays Provide (3). ECM Provides 12 Volts at 1C & 12 Volts to 1E & 1F E F G H 1G to Fuel feed Energizes fuel feed pump Pumps Relays

A. Auxiliary Relay E. J1-44 Fuel Pump1 Relay Control B. Auxiliary Relay Control F. J1-50 Fuel Pump2 Relay Control C. Fuel feed pump 2 G. Fuel feed Pump 1 D. Powertrain Relay Contacts – J1-73 H. Plug START SEQUENCE-3

• Momentarily Turn Key Switch to Start- ECM receives crank request on pin J2-22. START CONTACT ON

• ECM pin J1-63 Supplies 12 Volts to Bussman 3F which energizes Starter Relay. • Starter Relay then provides 12 Volts to Bussman 3H which in turn energizes Start Solenoid-Engine Cranks. “Bussmann” Connector #3 (Blue)

D C B A (6). 3H Provides 12 Volts to (5). ECM Supplies Starter Solenoid - 12 Volts to 3F Engine Cranks Energizes Starter E F G H Relay A. B+ to DLC E. Plug B. J1-72 Powertrain Relay Control F. J1-63 Starter Relay Control C. Plug G. Ground D. Plug H. Starter Solenoid

Starter Relay Control: 12v+ from ECM in Neutral 12. 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 Check/Charge/Replace. Requires 12 -14 volts ECM B+ 18 ga. Wire not Powered Must be Connected Directly to Battery or Battery Switch Faulty Battery Cable See Table for Proper Size Blown Fuse Check Fuses in SSEC Box Faulty Neutral Switch Replace Bad Starter Solenoid or Motor Replace Shift Control in Gear Take Out of Gear Faulty Starter Relay Check Relay in SSEC Box Hydro Lock Remove . Look for Water in the Cylinder Engine emergency Stop switch activated Clear DTC code Engine Cranks But Will Not Start Possible Cause Remedy Faulty Fuel Pump Note That Low Pressure and High feed Pumps Are Operating Insufficient Fuel Supply Check Fuel Supply Shut Off Valve, Check Fuel Filter. - Requires 60 PSI Fuel Pressure Insufficient Cranking RPM Check Battery Voltage. Voltage Should Be Over 12 volts Bad/Old Fuel Replace Insufficient Fuel Supply Approximately 60 PSI. Fuel Pressure Must Be Adequate at Wide Open Throttle at Full Load Active Trouble Code See Dealer Leaky Valves See Dealer Ensure a tune up is done every 100 hours or every season.

35 12. 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 Check Oil Level Plugged Fuel Tank Vent Check Vent Line for Blockage Insufficient Fuel Supply Approximately 60 PSI. Fuel Pressure Must Be Adequate at Wide Open Throttle at Full Load Restricted Anti-Siphon Valve Remove From Fuel Tank and Verify Spring Pressure Low Compression See Dealer Engine performance can be greatly affected by boat hull and prop condition.

High Speed Miss Possible Cause Remedy Water in Fuel Inspect/Clean/Replace Clogged Fuel Filter Change Fuel Filter Insufficient Fuel Supply Approximately 60 PSI. Fuel Pressure Must Be Adequate at Wide Open Throttle at Full Load Spark Plug or Wires Verify That All Plug Wires Are Attached Loose Ignition Connection Check That All Connectors Are Attached Detonation Verify Fuel Pressure and Fuel Quality NOTE: A Misfire will Cause a Trouble Code and RPM Reduction.

36 www.MarinePowerUSA.com 12. 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. Fuel Pressure Must Be Adequate at Wide Open Throttle at Full Load

Poor Fuel Economy Possible Cause Remedy Boat Hull Dirty Check-Clean if Necessary Incorrect Prop Size or Damage Verify with Dealer or Manufacturer Clogged Flame Arrester Check/Clean/Replace Low Engine Compression See Dealer Engine Running Too Hot or Cold Closed Cooled Engines Operate at 170°-190° F Incorrect Fuel Grade Replace Boat Overload Check Specifications Weight Distribution Check Specifications Plugged or Restricted Exhaust Check Exhaust System

37 12. 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, Engine Harness Connections

Oil Pressure - Low Possible Cause Remedy Low Oil Level in Crankcase Refer to Section13: Engine Identification on Page 15 Excessive Oil in Crankcase Remove Excess Oil. Refer to Section 3 : Engine Identification on Page 8 for Correct Oil Level Erroneous Oil Gauge Readings Contact Dealer to Perform a Mechanical Oil Pressure Check Incorrect Dipstick See Dealer Incorrect Oil Viscosity or Diluted Change to Proper Oil Oil Pump Malfunctioning See Dealer Excessive Bearing Clearance See Dealer Low Oil Pressure Will Set a Trouble Code and Will Reduce Engine RPM. Oil Pressure as Low as of 5 lbs. at Idle is Acceptable. At 2000 RPM 30 lbs. is Acceptable.

Oil Pressure - High Possible Cause Remedy Oil Too Thick - Wrong Viscosity Change to Proper Oil Erroneous Oil Gauge Readings Contact Dealer to Perform a Mechanical Oil Pressure Check Clogged or Restricted Oil Passage See Dealer Oil Valve Relief Valve Stuck Closed See Dealer

38 www.MarinePowerUSA.com 12. 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 8 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 Defective Rings See Dealer Defective Cylinders See Dealer Excessive Bearing Clearance See Dealer The Amount of Oil Used is Greatly Dependent Upon Engine Speed. Oil Usage Will be Greater at Higher RPM’s.

Engine Overheating - Verify if Engine is Actually Overheating Possible Cause Remedy Low Coolant Level Add Coolant. Refer to Bleeding Procedure if Coolant was Low or Not Flowing into Tank Clogged Sea Water Intake Clear Intake. Ensure That All Hoses After the Intake are Clear Clogged Sea Water Strainer Clean Sea Strainer Loose Hose Connections Check and Tighten Clamps Sea Water Hose Kinked or Collapsed Verify Hose Routing and Condition Obstruction in Cooling System Verify that Engine/Transmission Oil Cooler is not Clogged with Debris Sea Water Pump Impeller Worn Replace Antifreeze Not Properly Mixed Mix to a 50/50 Ratio Heat Exchanger Core Plugged Verify that Engine Heat Exchanger Ends are not Clogged Alternator Drive Belt Broken Replace

39 12. Trouble Shooting Water in Engine Cylinder or Base Possible Cause Remedy Operator Error See Section 7: Precautions on Page 16. 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. REMOVE Water from Engine Immediately Defective Exhaust Riser Gasket Contact Dealer. REMOVE Water from Engine Immediately Defective Exhaust Manifold or Riser Contact Dealer. REMOVE Water from Engine Immediately Cylinder Leak Contact Dealer. REMOVE Water from Engine Immediately Cracked Block or Cylinder Head Contact Dealer. REMOVE Water from Engine Immediately Intake Manifold Gasket Contact Dealer. REMOVE Water from Engine Immediately Incorrect Engine Rotation Contact Dealer. REMOVE Water from Engine Immediately Remove water by removing spark plugs and turning the engine over by hand. Once water is removed spray cylinder with Marvel Mystery Oil or 2-Cycle Engine Oil. Drain all the oil and change the oil filter(s). Again, turn the engine over by hand to circulate the oil. Contact your dealer immediately to make the required repairs. Upon completion of repairs, run the engine and again change the oil.

40 www.MarinePowerUSA.com 13. Installation Instructions NOTE: Before shipment, each engine has been careful- Engine Rotation the oil pan or other components located in that area and ly tested and inspected. It may be necessary to delete the hull. Directional references used in this section are given as or add oil from the engine and transmission for various if standing behind the boat, looking forward: engine installations. If engine is equipped with a closed Cooling System cooling system, it is imperative to fill the system with a • Front of boat is bow Closed cooled engines use a combination of freshwater 50/50 mix of base antifreeze and clean • Rear of boat is stern coolant (50% antifreeze + 50% water) and seawater for fresh water. Failure to use a 50/50 mixture of antifreeze cooling. The closed cooling system will operate at and water can result in engine damage. • Right side is starboard 170° - 190° F. The system is monitored by the water (See Section 3: Engine Identification) • Left side is port temperature gauge on the instrument panel and, in the case of EFI, the Engine Control Module. On EFI engines Engine Compartment The raw water (or Sea Water) pump is located at the the ECM will activate the POWER REDUC-TION MODE front of the engine on the crankshaft pulley. Engine if the engine temperature reaches 210° F. The The engine compartment should be well-planned giving rotation can be determined by looking at the stern end POWER REDUCTION MODE reduces RPM to consideration to accessibility and ventilation. Engines of the engine and observing the flywheel rotation. Do approximately 2500. The cooling system must receive must have air as well as fuel to operate efficiently. not assume engine rotation by looking at the propeller a sufficient amount of sea water under all operating The battery should be located as close as possible to rotation; it may not be the same. This information is conditions to operate properly. Cooling water may be the starter motor so that the battery leads can be kept critical when ordering parts for your engine. supplied from a stern drive unit or a through hull inlet short. EFI engines equipped with the SMART START scoop. ENPACS mated with stern drives that have water option have a direct connection to the battery or battery Left Hand Engines: CCW or Normal Rotation pumps in the drive leg can use the water supply from switch. ENGINE WIRING HARNESS Right Hand Engines: CW or Opposite Rotation the leg without using an impeller seawater pump. If the INCLUDES NOTATION ON RED/WHT WIRE. DI ENGINES ARE NOT AVAILABLE ENPAC is equipped with Closed Cooling, a sea water Engine Mounting pump will be part of the and a IN RIGHT HAND ROTATION Engine installation is very important. If the angle is severe (over 12 degrees) oil capacity may need to Engine Bed be adjusted. The engine bed should be of horizontal design and heavily constructed to maintain engine alignment. All of the thrust used in moving the boat is transferred to the hull through the engine bed. The standard engine has support mounts that are intended to be used on engine beds arranged for 22½” - 24” bolt centers. Use adequate bolts for each support. Make certain 41 there is no interference on the underside of the engine between DANGER

WARNING 13. Installation Instructions through hull inlet scoop must be used. In that case, the Emission-Related through-hull fitting and sea cock should be placed as Installation Instructions close to the engine as possible and be one size larger CAUTION than the water pump inlet. The water pump inlet scoop Failing to follow these instructions when installing a DO NOT operate engine without water being should face the bow of the boat in an area where there certified engine in a vessel violates federal law (40CFR supplied to raw water pump as damage to the are no obstructions. Obstructions could cause water 1068.105(b)) and is subject to fines or other penalties impeller and engine will result. turbulence and prevent a solid stream of water from as described in the Clean Air Act. The installer and/or entering the sea scoop. Regardless of the supply (stern vessel manufacturer must meet the evaporative Exhaust Piping drive or inlet scoop) the coolant water inlet hose must emission requirements of 40 CFR part 1060 and CFR IMPORTANT: The boat manufacturer or installing be of a non-collapsing type. If a through hull inlet scoop 1045.112. dealer (or individual) is responsible for properly locating is used, it is highly recommended that a sea strainer Any manufacturer installing a high performance engine the engine and installing the exhaust system. Improp- of adequate size and capacity be installed between the must use enhanced evaporative control systems on any er installation may allow water to enter the exhaust sea cock and engine sea water pump. If no sea strainer boat that is manufactured for sale, sold, or offered for manifolds and engine cylinders and severely damage is installed, periodically check the cooling inlet piping sale in California, or that is introduced, delivered or the engine. Damage caused by water in the engine and hose to clear debris from engine and transmission imported into California for introduction into commerce. will not be covered by the Marine Power warranty, oil coolers. Debris entering the cooling system is one of unless this damage is a result of defective parts or the main causes of overheating. Enhanced evaporative control system has designed the workmanship by Marine Power. system components to meet or exceed the diurnal and The ABYC and other industry standards require the use permeation design specifications listed in the following ENPACS, SPORTPACS, JETPACS AND TOWPACS of a seacock on certain types of applications to stop table throughout the useful life of the engine. are equipped with a wet exhaust system in which the entry of water in the event of a leak in the cooling exhaust is mixed with water in the exhaust risers. This system. The seacock must provide a minimum restric- PERMEATION DIURNAL TEST water cools the exhaust and allows the use of heat tion to water flow. A 90 degree ball valve with a lever STANDARDS STANDARDS TEMP resistant rubber hose on the riser outlets. Follow these [grams per sq. meter [grams per gal. [degrees Celsius] quarter turn handle is the most commonly used type. per day] per day] general guidelines when designing and installing the exhaust system. SPORTPACS AND TOWPACS use thru-hull fittings to Fuel Hoses 15.0 — 23 ± 2 supply cooling water to the sea water pump. Fuel Tank 1.5 — 28 ± 2 Use heat resistant hose that complies with specifica- Trailerable Boat 0.40 25.6 – 32.2 tions SAE J2006 or UL 1129 (ABYC standard). Exhaust Non-trailerable Boat 0.16 27.6 – 30.2 hoses should be 4” on dual outlet systems. 6.2L and larger engines should use 5” on single outlet systems.

42 www.MarinePowerUSA.com 13. Installation Instructions Sharp bends should be avoided. proper routing and to prevent over stressing the exhaust wire to the starter post as the voltage drops excessively at this location during starting. Exhaust hoses should be connected straight on the riser manifolds and risers. outlets. Internal flappers may be required on naturally aspirated Batteries 6.0 and 6.2L engines. Exhaust back pressure test should be preformed to Tapered post connections with wing nut connections ensure that exhaust components are adequately sized. Applications with through transom exhausts must be can be used. The tapered posts must be used for the Exhaust back pressure should be between 1-3 PSI. equipped with exhaust flappers to prevent the reverse engine battery cables while the wing nut connections Some back pressure is necessary to prevent water flow of water into the engine. Exhaust outlets should be should only be used for accessories. We highly recom- intrusion. Do not go below 1 PSI. above the water line with the boat at rest to minimize mend that wing nuts be replaced with regular nuts to Exhaust risers must be the suggested distance above engine back pressure. increase the tightness of the connections. the water line. Install riser spacers if necessary. Every exhaust connection should be secured with at Pay particular attention to ground connections. EFI A minimum of 18” of exhaust hose must be installed least 2 hose clamps. The clamps should be stainless engines are very dependent on secure ground connec- between the exhaust risers and the collector, Y-pipe, steel and at least 1/2” wide. tions. See typical ground location. or first angular fitting. This portion of the Electrical Connection Dual Engines exhaust hose must have a downward slope of 1-1/4”/ ft. for conventional inboards and a downward slope NOTE: Marine Power EFI engines are equipped with Batteries: Vessels with twin engines should have a of 7/8”/ft. for V-drives. Some OEM installations may “Smart Start” this feature is common in late model battery for each engine. The battery switch should be different from these specifications but these installa- automobiles but is new to the boating industry. This positioned so each engine is running off its own battery. feature enables the operator to start the engine by tions have been carefully evaluated by MARINE POWER Battery Isolators and the OEM. momentarily engaging the key switch, it is not necessary to hold the key switch. The ECM maintains Many boats are equipped with auxiliary batteries. Such After the first 18” the exhaust system must have a drop the starter engagement until the engine starts. Once batteries are used to operate stereos, etc. Battery of 1/2”/ft. Measure exhaust riser height as shown. the engine starts, the ECM prevents the starter from isolators can be used to charge an auxiliary battery. In Minimum exhaust riser height should be 15” on 6.0 and engaging even if the operator mistakenly turns the key these cases, the alternator output is connected to the 6.2L engines. All others should be 13”. switch. To ensure proper operation of this feature, the center post on the isolator instead of the starter. The The slope in the exhaust hose and components must engine wiring harness includes an 18 gauge wire coiled owner should familiarize himself with the isolator’s be routed so that no low point exists in the system by the starter. This wire must be connected directly to operation. where water may be retained. The muffler, collector and the battery or the battery switch. Do not connect this exhaust hoses must be adequately supported for

43 13. Installation Instructions Engine Battery Specifications motor, never plumb or tee into the main engine fuel above the bottom of the fuel tank. USCG REGULATIONS system. The auxiliary engine shall have its own fuel require that the fuel pump should be within 12” of the Model Minimum Required Rating pick up tube and fuel filter/water separator from the engine (excepting Airboats). fuel tank. Plumbing into the main engine fuel supply The Racor fuel/water separator should NEVER be 4.3L 550 CCA will cause damage to the engine and fuel pump system. placed on the outlet side of the Aero Motive fuel pump. 650 CCA 5.3L Fuel Pump Location: If the Aero Motive fuel pump The fuel filter/water separator should also be mounted 6.2LL 750 CCA is relocated from its mounting location on the engine within 12” from the bottom of the fuel tank. it must be placed as close to the fuel tank as possi- Battery Cable Length Requirements ble. The maximum distance from the fuel tank pick up Hoses and Fittings: Use only USCG Approved fuel lines. Make sure that the fuel line routing is not Cable Length Cable Gauge tube should be no more than 30”. The fuel pump must touching any sharp edges. Fittings should be full flow Up to 3.5 ft. 4 also be placed as low to the bottom of the fuel tank as possible. Using the lowest point on the bottom of design and not restricted tight 90 degree elbows. 3.5 - 6.0 ft. 2 the fuel tank, mount the fuel pump no more than 12” 6.0 - 7.5 ft. 1 7.5 - 9.5 ft. 0 9.5 - 12 ft. 00 12 - 15 ft. 000 15 - 19 ft. 0000

Special Fuel Instructions for 6.2 LT4 Engines Fuel Supply: The fuel supply pick up tube, fuel lines, and fittings shall be no smaller than 1/2” LT4 FUEL PUMP PT # 438627 inside diameter between the fuel tank and the Aero FILTER CASE (10/100 MICRON) Motive high-pressure fuel pump. The fuel pump must PART # 395536 also have the supplied serviceable 100 Micron filter FILTER ELEMENT 10 MICRON installed on the inlet side of the fuel pump. Some PART # 395538 installations use an in-tank fuel pump. In these FILTER ELEMENT 100 MICRON IN-TANK LT4 PUMP PT # 438639 cases the 100 micro filter or water separator is not PART # 395548 44necessary. Always mount a 10 micro filter www.MarinePowerUSA.com between the pump and the injectors. When using an auxiliary engine such as an outboard 13. 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 intercooler heat rejection. Intercooler radiator should be large enough to maintain Manifold Air Temperature at WOT. Please note there are 2 bleed points on the LT4 intercooler. Verify that coolant is flowing through the system before before running the engine at higher rpm's.

WARNING: The LT4 Is a Premium 93 Octane REQUIRED engine. The engine will operate at significantly reduced power output with octane levels down to 90. Operating the LT4 on fuel below 90 Octane can result in engine damage and or failure! Such failure will not be covered under Warranty!

45 13. Installation Instructions Adapter Harness For Analog Instrumentation

46 www.MarinePowerUSA.com

13. Installation Instructions Heater Connections

47 13. Installation Instructions Prestart Checklist tions with mechanical shift. If the transmission 8. On jet drive applications, check for proper operation is equipped with electric shift, check for proper of the reverse bucket and adjust as needed. 1. Check engine, transmission and V-drive (if applica- operation of the shift solenoids (ahead and astern). ble) oil levels. Also check for any oil leaks and repair 9. Inspect the fuel system for leaks and repair as Refer to your transmission operation manual. as needed. needed. 7. On inboard, V-drive and stern drive applications 2. Check that all engine drain plugs are installed and 10. Check that all engine mounts are tight verify that the engine will not start unless the shift- tightened. New engines may be shipped with drain er is in the neutral position. 11. Check that the battery is secure, and that all plugs removed electrical connections are tight. 3. If engine is equipped with optional closed cooling system, check for proper coolant level. Closed cooling systems must be filled with a 50/50 mixture of ethylene glycol based anti-freeze and clean fresh water. (See Routine Maintenance Section for “Filling” instructions) When proper- ly filled, ensure that any/all fill caps, fittings and hoses are properly secured and not leaking. 4. If engine is raw water cooled check the system for leaks and correct as needed. 5. On engines equipped with Electronic Throttle Control (ETC) there may be a cable routed from the throttle control lever at the helm to a potenti- ometer located in the engine compartment. Make certain that this cable operates freely and is properly adjusted. The adjustable potentiometer Potentiometer stop screws must not be used as the stop for Assembly the throttle lever/cable assembly at the helm. 6. Check the transmission shift cable/lever adjust- ment on Inboard, V-drive and stern-drive applica-

48 www.MarinePowerUSA.com ELECTRONIC THROTTLE ASSEMBLY

THROTTLE Clockwise LEVER

POTENTIOMETER CABLE ATTACHMENT CABLE ATTACHMENT

SET SCREWS POTENTIOMETER OPERATION

THE THROTTLE LEVER ROTATES APPROXIMATELY 80 DEGREES. 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. IF THE OUTPUT VOLTAGES ARE ABOVE OR BELOW THESE SETTINGS AN “OUT OF RANGE” DTC WILL SET AND THE THROTTLE PLATE WILL NOT OPEN OR CLOSE. LIKEWISE, IF THE DUAL OUTPUT VOLTAGES DIFFER BY MORE THAN 8%, A “CORRELATION” DTC WILL SET, AND THE THROTTLE PLATE WILL NOT OPEN OR CLOSE. THE SET SCREWS ARE USED TO ACCURATELY ADJUST THE OUTPUT VOLTAGES. THEY ARE NOT TO BE USED AS STOPS FOR THE THROTTLE CABLE. SUCH USE WILL CAUSE A CORRELATON DTC. DTC’S WILL AUTOMATICALLY RESET WITH AN IGNITION SWITCH RECYCLE. IF THE SET SCREWS ARE IMPEDING LEVER OPERATION THEY MUST BE BACKED OUT. IF A CORRELATION DTC CONTINUES TO SET, THE POTENTIOMETER SHOULD BE REPLACED AS IT IS PERMANENTLY DAMAGED. IF THE OUT OF RANGE DTC IS SETTING AS SOON AS THE IGNITION IS TURNED ON, THE LIKELY CAUSE IS MIS- ADJUSTMENT OF IDLE OUTPUTS. IF THE OUT OF RANGE DTC OCCURS AT WOT, THE WOT OUTPUTS ARE OUT OF ADJUSTMENT. POS DESCRIPTION WIRE COLOR POTENTIOMETER A PPS 1 5VOLT REF GRAY

B PPS 1 SIGNAL BLUE C PPS1 RETURN BLACK D PPS 2 5VOLT REF GRAY/WHT E PPS 2 SIGNAL BLUE/WHT F PPS 2 RETURN BLACK/WHT

D PPS2 5V REF C PPS1 RETURN E PPS2 SIGNAL B PPS1 SIGNAL F PPS2 RETURN A PPS1 REF

PPS1 VOLTAGE IS DETERMINED BY MEASURING BETWEEN PPS 1 SIGNAL AND PPS1 RETURN (A AND C). PPS2 VOLTAGE IS MEASURED BETWEEN PPS2 SIGNAL AND PPS2 RETURN(E AND F). CONNECTOR WILL HAVE TO BE BACK PROBED WITH IGNITION ON. Warranty Registration Transfer Please complete this form when engine ownership has been transferred. Transfer Registration To:

Date of Transfer (MM/DD/YY)

Engine Serial Number Engine Serial Number (If Dual Application)

Last Name First Name MI

Street Address

City State Zip Code

New Owners Phone Number 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

49 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

50 www.MarinePowerUSA.com Service Log Date Service/Maintenance Performed Performed By Operating Hours

51 Service Log Date Service/Maintenance Performed Performed By Operating Hours

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Copyright 2016 Marine Power 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. Marine Power 17506 Marine Power Industrial Park, Ponchatoula, LA 70454 USA www.MarinePowerUSA.com