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'maine Power Owners Manual'




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Engine
Owners
Manual
I N CLU DES
Routine Guidelines
Electronic Fuel Injection
SECTION ONE
OWNERS OPERATION MANUAL
Pages
1 General Emissions Coverage 23
2 Carbon Monoxide Exposure 3
3 4
4 Engine Identificatio n
5 Emissions Control Information 4
6 Warranty Trial Informatio 4
7 EFI Introduction and Descriptio 5
8 Marine Power Domestic Distributor 6
9 Engine Specification s
30L181 CI 7
43L262 CI 8
57L350 CI 9
60L364 CI 10
74L454 CI 11
81L495 CI 12
82L502 CI 13
500X530 X
10 A Word To The r
Copyright 1994
Revised 0603
All rights reserved No part of this book may be reproduced or utilized in any form or by any means electronic including photocopying recording or any
information storage and retrieval system without permission in writing
from MARINE POWER HOLDING LLC
GENERAL EMISSIONS WARRANTY COVERAGE
C ALIFORNIA EM ISSIONS C ONT R OL
W ARR ANT Y ST AT EM ENT
Y OUR W ARR ANT Y R IG HT S AND OBLIG ATIONS
T he California Air R esources board and Marine Power Holding LLC is pleased to explain the emission control system warranty on your 2003 inboard
engine In C alifornia new inboard engines must be designed built and equipped to meet the States stringent anti smog standards Marine Power
H olding LLC must warrant the emission control system on your inboard engine for the periods of time listed below provided there has been no abuse
neglect or improper m aintenance of your inboard engine
Your em ission control system may include parts such as carburetor or fuel injection system the ignition system and catalytic converter Also included
may be hoses belts connectors and other assemblies
W here a warrantable condition exists Marine Power Holding LLC will repair your inboard engine at no cost to you including diagnosis parts and labor
M ANUFACT URER S W ARR ANT Y COVERAG E
For 20032008 spark ignition inboard engines select emission control parts from m odel year 20032008 inboard engines are warranted for 2 years
For 2009 and later spark ignition inboard marine engines select emission control parts from model year 2009 and later inboard engines are warranted
for 3 years
OW NERS W ARR ANT Y RESPONSIBILIT IES
As the inboard engine owner you are responsible for the performance of the required maintenance listed in your owners manual Marine Power H olding
LLC recom mends that you retain all receipts covering maintence on your inboard engine but M arine Power H olding LLC cannot deny warranty solely
for the lack of receipts or your failure to ensure the perform ance of all schedule maintence
As the inboard engine owner you should however be aware that Marine Power H olding LLC may deny you warranty coverage if your inboard engine or
part has failed due to abuse neglect or improper maintence or unapproved You are responsible for presenting your inboard engine to a Marine
Power H olding LLC distribution center as soon as a problem exists T he warranty
repairs will be complete within a reasonable amount of time not to exceed 30 days
1 MAR IN E PO W ER the Company warranties each new MAR IN E PO W ER propulsion engine and factory installed accessories designed built and
equipped
with all applicable regulations adopted by the Air R esources Board pursuant to its authority in C hapters 1 and 2 Part 5 D ivision26 of the Health
and Safety
C ode and to be free from defects in materials and workmanship that cause the failure of a warranted part to be identified in all material respects to
that part
as described in the engine manufacturer application for T he warranty shall commence on the date of the first retail purchase and extends to
original and subsequent purchasers H owever in no event shall the
duration of this W arranty exceed two 2 years measured from the original retail sale date
3 Any warranted part that is not scheduled for replacement as required maintenance in the written instructions in the owners manual will be
warranted for the
two 2 year warranty period If the part fails during the period of warranty coverage the part will be repaired or replaced by Marine Power at a
warranty
station Any such part repaired or replaced under warranty will be warranted for the remainder of the period
4 Any warranted part that is scheduled only for regular inspection in the written instructions in the owners manual will be warranted for the two
2 year warranty
period A statement in such written instructions to the effect of repair and replace as necessary does not reduce the period of warranty coverage Any
such part repaired or replaced under warranty will be warranted for the remaining warranty period
5 Any warranted part that is scheduled for replacement as required maintenance in the written instructions in the owners manual will be warranted
for the period
of time before the first scheduled replacement date for the part If the part fails before the first scheduled replacement the part will be repaired or
replaced
by Marine Power at a warranty station Any such part repaired or replaced under warranty will be warranted for the remainder of the period to the firs
scheduled replacement point for the part
6 R epair or replacement of any warranted part under the warranty provisions of the article will be performed at a warranty station at no charge
to the owner
W arranty services and repairs will be provided at all Marine Power distribution centers and trained marine dealers
7 T he engine owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted
part provided
that such diagnostic work is performed at a warranty station
8 Marine Power is liable for damages to other engine components proximately caused by a failure under warranty of any warranted part
9 T hroughout the two 2 year warranty period Marine Power will maintain a supply of warranted parts sufficient to meet the expected demands for
such parts
10 Any replacement part may be used in the performance of any warranty maintenance or repairs and will be provided without charge to the owner Such
usage
will not reduce Marine Powers warranty MAR IN E PO W ER distributor or dealer must be advised of any warranty related problem prior to the
expiration of the T his W arranty w ill not apply to
A Use of an accessories or parts not manufactured or sold by MARINE PO W ER
B N eglect failure to follow maintenanc e schedules accident abnormal operations m isuse negligence improperly maintained improperly
operated or installed racing or engine modification Problems arising from installation application exhaust to engine fuel lines to the engine
propping cooling to the engine or engine damage due to defective electrical hookups
R ust corrosion or effects of weather
D W ater inversion through exhaust
E D etonation or operation with fuels oils or lubricants which are not suitable for use with this product Detonation causes Poor fuel quality
overloading of engine improper gear or propeller selection engine overheating excessive back pressure incorrect ignition timing excessive
total timing
F R eimbursement for haulout launch towing storage charges rental charges of any type inconvenience of any type loss of time or income
expense of returning a M AR IN E PO W ER product to a service facility towing lodging loss or dam age to personal Addon or modified parts as
defined in C C R section 1900 b1 and b10 T itle 13 that are not exempted by the Air R esources Board will not be
used T he use of any nonexempted addon or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claim made in
accordance with this article statement Marine Power will not be liable under this statement to warranted failures of warranted parts caused by the use
of nonexempted addon or modified part
14 T he following parts are covered by this general emissions warranty statement
A Fuel Metering System
1 C arburetor and internal parts andor pressure regulator or fuel injection system
2 C old start enrichment system
3 Intake valves
B Air Induction System
1 Intake m anifold
2 Air Filter
C Ignition System
1 Spark Plugs
2 Electronic ignition system
3 Spark system
4 Ignition coil andor control module
5 Ignition wires
D Lubrication System
1 O il pump and internal parts
E Positive Crankcase Ventilation P C V S ystem
1 PC V valve
2 O il filler cap
F Exhaust System
1 Exhaust m anifold
2 Exhaust valves
G M iscellaneous Item s U sed in A bove S ystem s
1 H oses clamps fittings tubing sealing gaskets or devices and mounting hardware
2 Pulleys belts and idlers
3 Vacuum temperature check and timer sensitive valves and switches
4 Electronic controls
15 R easonable access must be provided to the product for warranty service Removal andor replacement of boat partitions or material because of
boat
design for necessary access to the product is not covered
16 W arranty service must be requested by delivering the product for inspection to the retailer from whom the product was purchased or any
convenient
marine service center
17 Proof of W arranty must be provided at time of request for W arranty service A properly completed W arranty R egistration Sea T rial form
should be on
file with MARINE PO W ER O therwise a valid bill of sale will be required for proof of purchase date
18 All incidental andor consequential damages are excluded from this W arranty Implied warranties are limited to the life of this W arranty All
implied
warranties including fitness for a particular purpose or otherwise are disclaimed in their entirety after expiration of the appropriate two
2 year warranty period T his W arranty gives you specific rig h ts an d you m ay also have other rights which m ay vary from state to state Som e
jurisdictions do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to
19 MAR IN E PO W ER reserves the right to change or improve design of any product previously assembled without notice and without In the
event that a warranty claim is required outside of the continental U nited States with the exception of Alaska and H awaii there may be additional
charges to the engine owner AnyAll litigations must be filed within the State of Louisiana Parish of T angipahoa MAR IN E PO W ER will not warranty
any engine sold outside the continental U nited States with the exception of Alaska and H awaii unless com petent and trained personnel and available
to provide service to the engine
W0020300
R EV 04
2 CARBON MONOXIDE EXPOSURE
CAUTION CARBON MONOXIDE EXPOSURE
Carbon Monoxide is a odorless colorless and tasteless gas that cannot be smelled seen or tasted
Sustained exposure to carbon monoxide gas may lead to brain damage or Monoxide is a hazardous gas that is produced when items containing carbon are
burned Items such as
but not limited to wood coal gasoline natural gas propane or oil Carbon Monoxide CO is found in many
areas such as any type of internal combustion engines heaters charcoal grills cooking ranges and any other
open flame appliances There are many possible variables for the accumulation of carbon monoxide boat speed vessel proximity to other vessels or
structures are just a few of the possible variables that
would permit exposure to carbon monoxide gases It is important that regular inspections of the exhaust system
are conducted and maintenance is properly performed by a qualified air circulation in all areas of your boat are necessary in order to prevent
buildup of carbon contact your boat manufacturer if you have questions regarding these hazards For more safe boating practices andor carbon monoxide
poisoning on recreational boats contact the Marine Manufacturers Association United States Coast Guard
200 East Randolph Drive Suite 5100 Office of Boating IL 606016528 CG
Headquarters 2100 Second Street
Washington DC 20593
Boat Yacht Council Inc Solomons Island MD
3
3 pleasure and peace of mind derived from your new engine is in direct proportion to the amount of care that it is given
We have tried to include as much as possible in our updated Engine Owners Manual to help you READ THIS AND COMPLETELY before attempting to operate
your MARINE POWER engine Become familiar with and the maintenance schedules If there is anything you do not completely understand contact your POWER
dealer or distributor
This manual contains five 5 sections
Section ONE Owners Operation M anual Page 1
Section TWO G eneral Information Page 18
Section T HR EE R outine M aintenance Page 25
Section FOUR Engine Diagram s Page 37
Section FIVE T G uide Page 49
4 ENGINE Marine Power engine is equipped with an Engine tag
also known as a Serial Number tag This tag contains information model number and serial number that will be any warranty work if necessary can be
done
5 EMISSIONS CONTROL INFORMATION
M AR INE PO W ER
EM ISSIO N C O N TR O L IN FO R M A TIO N
TH IS EN G IN E C O N FO R M S TO 2003 C A LIFO R N IA EM ISSIO N R EG U LA TIO N S FO R SPA R K
IG N ITIO N M A R INE EN G INES
ENG INE FAM ILY 3M PEM 060 100 ENG INE 57L
FUEL UNLEAD DISP 042003
SPAR K PLUG G ASOLINE DAT E OF 060 022 IN
EM ISSION CONT ROLS 479111 M FR
EC M G AP
SEE O PER A TO R S M A N U A L FO R M A IN TEN A NC E SPEC IFIC A TIO N S
M AR INE PO W ER
EM ISSIO N C O N TR O L IN FO R M A TIO N
TH IS EN G IN E C O N FO R M S TO 2003 C A LIFO R N IA EM ISSIO N R EG U LA TIO N S FO R SPA R K
IG N ITIO N M A R INE EN G INES
ENG INE FAM ILY 3M PEM 060 100 ENG INE 60L
FUEL UNLEAD DISP 042003
SPAR K PLUG G ASOLINE DAT E OF 060 022 IN
EM ISSION CONT ROLS 479111 M FR
EC M G AP
SEE O PER A TO R S M A N U A L FO R
M A IN TEN A NC E SPEC IFIC A TIO N S
6 WARRANTY REGISTRATION SEA TRIAL he Federal Boat Safety Act of 1971 requires that registration of marine products sold in the United States be
maintained by the dealers of those products It is imperative that MAR IN E PO W ER H O LD IN G LLC receive your W ARR ANT Y R EG IST R AT IONSE A T
R IAL
form properly com pleted for warranty purposes and to com ply with federal regulation T his registration also enables us to contact you if it should
become necessary to change or improve the product for your protection W AR R ANT Y R EG IST R AT ION M UST BE R EC EIVED W IT HIN 10 DAY S
AFT ER DAT E OF PURC HASE BY FIRST OW NER NONCOM PLIANCE M AY VOID ALL W ARR ANT IES Please read the Limited W that is included with your engine
registration papers and in this manual This document explains your warranty coverage Please note
that no warranty repairs are to be perform ed without prior authorization from the Marine Power D istributor in your area C ontact your selling for
any required w arranty 7 EFI INTRODUCTION AND DESCRIPTION
Another feature of EFI is the ability to develop
W HAT IT IS for the ECM which are specific to each
application For example EFI installed in a inboard Fuel Injection EFI has become the industry boat application will have little in common
with EFI
standard for marine engines EFI is the basic term which installed in a jet boat The calibration is tailored to to any fuel delivery system
which uses a computer maximum power and efficiency for each determine how much fuel to add at a specific moment in
time Another benefit of fuel injection is the high level of
reliability in the components used Generally speaking a
carbureted engine begins to deteriorate as soon as it is
TW O B ASI C TYP ES purchased Fuel which sits for extended time attacks the
carburetor and begins to hamper performance The older
There are two basic types of EFI used in the marine style points ignition system also breaks down with age due
industry Throttle Body Injection TBI and Multiport Fuel to friction which wears out the components being used to
Injection MPFI MFI PFI etc The TBI system is a wet control spark timing Within 2 or 3 years the fuel and
flow design which flows a mixture fuel and air through the spark delivery has deteriorated and the engine must be
intake manifold The PFI system flows air through the tuned up in order to restore the original power Also a
intake manifold then injects fuel towards the cylinder head side effect of this deterioration is that the engine may
to complete the mixture thus allowing the intake to be actually be damaged by being over or under to flow air only PFI systems are slightly
than the TBI systems Combustion requires a EFI also offers the owner a level of protection which older
finely atomized mixture to ignite In the wet flow TBI system engines did not have as standard features The ECM
some of the fuel will condense or collect on the intake walls monitors the temperature RPMs and other inputs and
and then pass into the combustion chamber When solid then makes decisions whether or not to allow the engine to
fuel passes into the combustion chamber it is not burned continue to run in the current conditions For example the
and subsequently it is passed out the exhaust This is why engine may be running above the ideal RPM if the ECM
the PFI systems are more efficient than the TBI systems detects that the RPM is over the calibrated rev limiter then
the ECM will reduce the RPMs to a level which the engine
can handle The rev limiter can protect the engine from a
HOW IT W OR K S
prop which is not correctly matched or is to loose for the
Engine Control Module ECM refers to the makes the necessary calculations to deliver fuel and
spark to the engine The ECM relies on input from sensors CAUTION CAUTION CAUTION
and switches to perform its calculations The ECM then
sends out its data along its output wires to the various To reduce the chance of personal injury ando r which it controls
dam age the follow ing instructions m ust be carefully inputs which the ECM uses are RPM throttle Proper
service and repair are important to the manifold absolute pressure coolant temperature of the service technician and the safe reliable
and a knock sensor With the data being collected form operation of all Electronic Fuel Injection EFI Marine
these sensors at a very high rate the ECM then calculates Power engines If part replacement is necessary the
the proper fuel to be delivered and the proper spark timing part must be replaced with one of the same part
to ignite the mixture number or with an equivalent part Do not use a
replacement part of lesser quality
The ECM delivers the fuel through injectors which are The service procedures recommended and solenoids The fuel is injected at high
pressures in this manual are effective methods of performing
of 30 to 40 PSI which creates a much finer mixture of fuel service and repair Some of these procedures require
and air The injector is pulsed for a length of time called the use of tools specially designed for the purpose
the Base Pulse Width BPW The BPW can be modified Accordingly anyone who intends to use a
for enrichment when cold a lean condition when hot replacement part service procedure or tool which is
enrichment when knock is detected and so on not recommended by the system manufacturer must
first determine that neither his safety nor the safe
operation of the engine will be jeopardized by the
B EN EFI TS FEATUR ES replacement part service procedure or tool selected
The primary benefit of fuel injection is the repeatability or
accuracy of the amount of fuel delivered BPW The fuel Note Under no circumstances should your EFI are very precise in their ability to
deliver fuel and be repaired or serviced except by an their accuracy over the entire life span of the Marine Power EFI trained
technician for service Prior authorization from area distributor is
required
8 MARINE POWER DOMESTIC Georgia South Carolina North W est Virginia Ark ansas Ok lahom a North M MARINE SERVICE
SOUTHERN MARINE SUPPLY
100 SW 16th Street 6600 Murray Street Suite 1
Fort Lauderdale FL 33315 Little Rock AR 72209
954 5250311 800 4322231 501 5625008 501 Email MARINE SERVICE
Louisiana M ississippi Alabam a Meeting Street Road P SC 29405 COMMERCIAL MARINE INC
843 5543732 800 7882231 5401 Paris Road
PO Box 16
N ortheastern United States Chalmette LA MARINE SERVICE OF NEW JERSEY 504 2717201
780 Vassar Avenue NJ 08701
908 9018404 888 2444735 Gulf Coast
DONOVAN MARINE
M ichigan W isconsin Ohio Illinois Indiana 400 N Carrollton Avenue 70119
M innesota Iow a North Dak ota South Dak ota PO Box 19100
N ebrask a New Orleans LA MARINE DISTRIBUTORS 504 4885731 800 3474464
1551 Michigan Avenue
PO Box 126 N orthern MI 48040 SEA POWER MARINE
810 3647653 800 3670987 333 Kennedy Oakland CA 94606
510 5339290 800 MARINE DISTRIBUTORS WEST South Thompson Road
Sun Prairie WI 53590 W ashington I daho NW United States and
608 8253878 800 9923878 W estern Canada
MARINE POWER Kentuck y M issouri Kansas 1140 36th Street MARINE DIST SOUTH Lewiston ID 83501
855 Springfield Highway Suite 104 208 7468621 208 TN 37072
615 8519456 Oregon W estern California
MARINE POWER OREGON
Tex as 6445 Crater Lake POWER CORPORATION Central Point OR 97502
6451 Rupley Circle 541 TX 77087
713 6446410 800 MARINE
3130 Pawnee TX 77054
713 7344171 800 California Arizona Nevada Haw aii
MARINE POWER WEST COAST
6310 Industrial CA 92504
909 9 ENGINE 30L 181 CID
C AR BU R ET ED
ENGINE TYPE INLINE 4
CRANKSHAFT HORSEPOWER HPKW 140 104
DISPLACEMENT LITERCID 30L 181 CID
BORE STROKE INCHES 400 x 360
COMPRESSION RATIO 9251
MAXIMUM RPM WIDE OPEN THROTTLE 4300 4600
IDLE RPM IN FORWARD GEAR 650 800 RPM
FUEL PUMP PRESSURE 4 7 PSI
OIL PRESSURE 2000 RPM 20 60 PSI
MINIMUM OIL PRESSURE IDLE 10 PSI
THERMOSTAT 143 F 62 C RAW WATER COOLER
160 F 71 C FRESH WATER COOLED
SPARK PLUG TYPE MR 43 LTS
SPARK PLUG GAP 035 IN 09MM
TIMING IDLE RPM 1 ATDC
TOTAL MAX TIMING ADVANCE 4000 RPM 23 TOTAL
FIRING ORDER 1342
ELECTRICAL SYSTEM 12 VOLT NEGATIVE GROUND
ALTERNATOR RATING 70 AMPS
RECOMMENDED BATTERY RATING MINIMUM 350 AMPS COLD CRANKING AMPERAGE
CRANKCASE OIL SAE 30 70 and Below SAE 40 70 and Above
TRANSMISSION OIL DEXTRON III
CLOSED COOLING FLUID 50 WATER 50 ANTIFREEZE
CAPACITIES
CLOSED COOLING APPROXIMATELY 10 US QUARTS
CRANKCASE OIL ADD 23 QT OIL FOR
APPROXIMATELY 4 US QUARTS
EACH OIL FILTER USED ON ENGINE
T R ANSM IISSIONS See Transm ission on P age 14
C R AT ED BY MAR IN E PO W ER IN C IN AC C O R D AN C E W IT H SAE J607 PR O P SH AFT RAT IN G W ILL VAR Y AC C O R D IN G T O
D R IVE U SED
SYNT HET IC O IL MAY BE SUBSTIT UT ED
AN Y T YPE H YD R AU LIC T R AN SMISSIO N FLU ID S W H IC H MEET ALLISO N T YPE C 3 SPEC IFIC AT IO N S
9 ENGINE 43L 262 CID
C AR BU R ET ED M PI
ENGINE TYPE V6
CRANKSHAFT HORSEPOWER HPKW 225 167 230 171
DISPLACEMENT LITERCID 43L 262 CID
BORE STROKE INCHES 400 x 348
COMPRESSION RATIO 941
MAXIMUM RPM WIDE OPEN THROTTLE 4300 4600 4200 4600
IDLE RPM IN FORWARD GEAR 650 800 RPM
FUEL PUMP PRESSURE 4 7 PSI
OIL PRESSURE 2000 RPM 20 60 PSI
MINIMUM OIL PRESSURE IDLE 10 PSI
THERMOSTAT 143 F 62 C RAW WATER COOLER
160 F 71 C FRESH WATER COOLED
SPARK PLUG TYPE 262 STD MR43T
43 VORTEC AC 41932
43L VORTEC MR43LTS
SPARK PLUG GAP 035 IN 09MM
TIMING IDLE RPM 2 Set At Factory
TOTAL MAX TIMING ADVANCE 4000 26
FIRING ORDER 165432
ELECTRICAL SYSTEM 12 VOLT NEGATIVE GROUND
ALTERNATOR RATING 70 AMPS
RECOMMENDED BATTERY RATING MINIMUM 350 AMPS COLD CRANKING AMPERAGE
CRANKCASE OIL SAE 30 70 and Below SAE 40 70 and Above
TRANSMISSION OIL DEXTRON III
CLOSED COOLING FLUID 50 WATER 50 ANTIFREEZE
CAPACITIES
CLOSED COOLING APPROXIMATELY 16 US QUARTS
CRANKCASE OIL ADD 23 QT OIL FOR
APPROXIMATELY 45 US QUARTS
EACH OIL FILTER USED ON ENGINE
See Transmission on Page 14
C R AT ED BY MAR IN E PO W ER IN C IN AC C O R D AN C E W IT H SAE J607 PR O P SH AFT RAT IN G W ILL VAR Y AC C O R D IN G T O
D R IVE U SED
SYNT HET IC O IL MAY BE SUBSTIT UT ED
AN Y T YPE H YD R AU LIC T R AN SMISSIO N FLU ID S W H IC H MEET ALLISO N T YPE C 3 SPEC IFIC AT IO N S
9 ENGINE 57L 350 CID
C AR BU R ET ED M PI
ENGINE TYPE V8
CRANKSHAFT HORSEPOWER HPKW 315 235 325335 242
DISPLACEMENT LITERCID 57L 350 CID
BORE STROKE INCHES 400 x 348
COMPRESSION RATIO 941
MAXIMUM RPM WIDE OPEN THROTTLE 4300 4600 4200 5000
IDLE RPM IN FORWARD GEAR 650 800 RPM
FUEL PUMP PRESSURE 4 7 PSI 39 PSI
OIL PRESSURE 2000 RPM 20 60 PSI
MINIMUM OIL PRESSURE IDLE 10 PSI
THERMOSTAT 143 F 62 C RAW WATER COOLER
160 F 71 C FRESH WATER COOLED
SPARK PLUG TYPE PREVORTEC MR43T
57 VORTEC AC 41932
VORTEC MR43LTS
SPARK PLUG GAP 035 in 060 in Platinium
TIMING IDLE RPM 8 10
TOTAL MAX TIMING ADVANCE 4000 26
FIRING ORDER LH 1 8 4 3 6 5 7 2 RH 1 2 7 5 6 3 4 8
ELECTRICAL SYSTEM 12 VOLT NEGATIVE GROUND
ALTERNATOR RATING 70 AMPS
RECOMMENDED BATTERY RATING MINIMUM 350 AMPS COLD CRANKING AMPERAGE
CRANKCASE OIL SAE 30 70 and Below SAE 40 70 and Above
TRANSMISSION OIL DEXTRON III
CLOSED COOLING FLUID 50 WATER 50 ANTIFREEZE
CAPACITIES
CLOSED COOLING APPROXIMATELY 18 US QUARTS
CRANKCASE OIL ALUM PAN APPROXIMATELY 7 US QUARTS
SHEET METAL PAN APPROXIMATELY 5 US QUARTS
JETPAC PAN WSINGLE FILTER 8 US QUARTS
JETPAC PAN WDUAL FILTERS 9 US QUARTS
See Transmission on Page 14
R A T E D B Y MAR IN E PO W ER IN C IN ACC O R D ANC E W IT H SAE J 607 PR O P SH AF T R AT IN G W ILL VAR Y AC C O R D IN G T O D R IVE U SE D
SYN T H ET IC O IL MAY BE SU BST IT U T ED
A N Y T Y P E HY D R AULIC T R ANSMISSIO N FLUID S W H IC H MEET ALLISO N T YPE C 3 SPEC IF IC AT IO N S
9 ENGINE 60L 364 CID
M PI
ENGINE TYPE V8
CRANKSHAFT HORSEPOWER HPKW 375 HP 5200 RPM
DISPLACEMENT LITERCID 6OL 364 CID
BORE STROKE INCHES 400 X 362 IN
COMPRESSION RATIO 941
MAXIMUM RPM WIDE OPEN THROTTLE 5200 RPM
IDLE RPM IN FORWARD GEAR 650 RPM 800 RPM JET EQUIPPED
FUEL PUMP PRESSURE 50 PSI 55 PSI WOT
OIL PRESSURE 2000 RPM 60 PSI
MINIMUM OIL PRESSURE IDLE 10 psi
THERMOSTAT 160 71 C Fresh Water Cooled Only
SPARK PLUG TYPE PLATINUM AC 12567759
SPARK PLUG GAP 59 15MM
TIMING IDLE RPM COMPUTER CONTROLLED
TOTAL MAX TIMING ADVANCE 4000 COMPUTER CONTROLLED
FIRING ORDER ELECTRICAL SYSTEM
12 VOLT NEGATIVE GROUND
ALTERNATOR RATING 70 AMPS
RECOMMENDED BATTERY RATING MINIMUM 350 AMPS COLD CRANKING AMPERAGE
CRANKCASE OIL SAE 30 70 and Below SAE 40 70 and Above
TRANSMISSION OIL DEXTRON III
CLOSED COOLING FLUID 50 WATER 50 ANTIFREEZE
CAPACITIES
CLOSED COOLING APRROX 24 US QUARTS
CRANKCASE OIL APPROX 65 QTS PLUS FILTERS
JETPAC PAN WSINGLE FILTER 7 US QUARTS
See Transmission on Page 14
R AT ED BY MAR IN E PO W ER IN C IN AC C O R D AN C E W IT H SAE J607 PR O P SH AFT RAT IN G W ILL VAR Y AC C O R D IN G T O
D R IVE U SED
SYN T H ET IC O IL MAY BE SU BST IT U T ED
AN Y T YPE H YD R AU LIC T R AN SMISSIO N FLU ID S W H IC H MEET ALLISO N T YPE C 3 SPEC IFIC AT IO N S
T BI HP RAT ING SAME AS MPI
9 ENGINE 74L 454 CID
ST AN D AR D C AR BU R ET ED PR EM IU M C AR BU R ET ED
E N G IN E T Y P E V8
CRANKSHAFT HORSEPOWER HPKW 330 246 380 282
DISPLACEMENT LITERCID 74L 454 CID
BORE STROKE INCHES 425 x 400
COMPRESSION RATIO 801 861
MAXIMUM RPM WIDE OPEN THROTTLE 4300 4600 4600 5000
IDLE RPM IN FORWARD GEAR 650 800 RPM
FUEL PUMP PRESSURE 4 7 PSI 4 7 PSI
OIL PRESSURE 2000 RPM 20 60 PSI
MINIMUM OIL PRESSURE IDLE 10 PSI
THERMOSTAT 143 F 62 C RAW WATER COOLER
160 F 71 C FRESH WATER COOLED
SPARK PLUG TYPE AC MR43T AC MR43T
SPARK PLUG GAP 035 IN 09MM
TIMING IDLE RPM 12 12
TOTAL MAX TIMING ADVANCE 4000 32 32
FIRING ORDER LH 1 8 4 3 6 5 7 2 RH 1 2 7 5 6 3 4 8
ELECTRICAL SYSTEM 12 VOLT NEGATIVE GROUND
ALTERNATOR RATING 70 AMPS
RECOMMENDED BATTERY RATING MINIMUM 350 AMPS COLD CRANKING AMPERAGE
CRANKCASE OIL SAE 30 70 and Below SAE 40 70 and Above
TRANSMISSION OIL DEXTRON III
CLOSED COOLING FLUID 50 WATER 50 ANTIFREEZE
CAPACITIES
CLOSED COOLING APPROXIMATELY 24 US QUARTS
CRANKCASE OIL ADD 23 QT OIL FOR ALUM PAN APPROXIMATELY 10 US QUARTS
EACH OIL FILTER USED ON ENGINE SHEET METAL PAN APPROXIMATELY 8 US QUARTS
See Transmission on Page 14
R AT ED BY MAR IN E PO W ER IN C IN AC C O R D AN C E W IT H SAE J607 PR O P SH AFT RAT IN G W ILL VAR Y AC C O R D IN G T O
D R IVE U SED
SYN T H ET IC O IL MAY BE SU BST IT U T ED
ANY T YPE HYDR AULIC T RAN SMISSIO N FLUIDS W HICH MEET ALLISO N T YPE C3 SPECIFICAT IO NS
T BI HP RAT ING SAME AS MPI
9 ENGINE 81L 495 CID
ST AN D AR D VOR T EC H IPER F H P2 H IPER F H P 3
E N G IN E T Y P E V8
CRANKSHAFT HORSEPOWER HPKW 385 287 450 335 550 410
DISPLACEMENT LITERCID 81L 496 CID
BORE STROKE INCHES BORE 425 10795MM STROKE 437 111MM
COMPRESSION RATIO 911
MAXIMUM RPM WIDE OPEN THROTTLE 4600 RPM 5000 RPM 5200 RPM
IDLE RPM IN FORWARD GEAR 650 RPM
FUEL PUMP PRESSURE 38 44 PSI
OIL PRESSURE 2000 RPM 50 80 PSI
MINIMUM OIL PRESSURE IDLE 10 PSI
THERMOSTAT 143 F 62 C RAW WATER COOLER
160 F 71 C FRESH WATER COOLED
SPARK PLUG TYPE PLATINUM MP PART 810E210
SPARK PLUG GAP 059 IN 15MM
TIMING IDLE RPM COMPUTER CONTROLLED
TOTAL MAX TIMING ADVANCE 4000 COMPUTER CONTROLLED
FIRING ORDER ELECTRICAL SYSTEM
12 VOLT NEGATIVE GROUND
ALTERNATOR RATING 70 AMPS
RECOMMENDED BATTERY RATING MINIMUM 350 AMPS COLD CRANKING AMPERAGE
CRANKCASE OIL SAE 30 70 and Below SAE 40 70 and Above 20W 50 SY NT HET IC
T R ANSM ISSION OIL DEXT R ON III
CLOSED COOLING FLUID 50 W AT ER 50 ANT IFREEZ E
CAPACIT IES
C LOSED C OOLING APPR OXIM AT ELY 24 US QUAR T S
C R ANK C ASE OIL A D D 1 Q T O IL FO R EA C H O IL A LU M PA N APPR OXIM AT ELY 10 US QUAR T S
FILTER U SED O N ENG INE SH EET M ETA L PA N APPR OXIM AT ELY 8 US QUAR T S
JETPA C PA N W SING LE FILTER 7 US QUAR T S
JE TPA C PA N W D U A L FILTER 8 US QUAR T S
T R ANSM ISSIONS See Transm ission on P age 14
R AT ED BY MAR IN E PO W ER IN C IN AC C O R D AN C E W IT H SAE J607 PR O P SH AFT RAT IN G W ILL VAR Y AC C O R D IN G T O
D R IVE U SED
SYN T H ET IC O IL MAY BE SU BST IT U T ED
AN Y T YPE H YD R AU LIC T R AN SMISSIO N FLU ID S W H IC H MEET ALLISO N T YPE C 3 SPEC IFIC AT IO N S
T BI HP RAT ING SAME AS MPI
9 ENGINE 82L 502 CID
C AR BU R ET ED M PI
E N G IN E T Y P E V8
CRANKSHAFT HORSEPOWER HPKW 450 335
DISPLACEMENT LITERCID 82L 502 CID
BORE STROKE INCHES 447 x 400
COMPRESSION RATIO 8751
MAXIMUM RPM WIDE OPEN THROTTLE 4300 4800 4600 5000
IDLE RPM IN FORWARD GEAR 650 800 RPM
FUEL PUMP PRESSURE 4 7 PSI 39 PSI
OIL PRESSURE 2000 RPM 20 60 PSI
MINIMUM OIL PRESSURE IDLE 10 PSI
THERMOSTAT 143 F 62 C RAW WATER COOLER
160 F 71 C FRESH WATER COOLED
SPARK PLUG TYPE AC MR43T
SPARK PLUG GAP 035 IN 09MM
TIMING IDLE RPM 12 12
TOTAL MAX TIMING ADVANCE 3500 32 Computer Controlled
FIRING ORDER 1843 6572
ELECTRICAL SYSTEM 12 VOLT NEGATIVE GROUND
ALTERNATOR RATING 70 AMPS
RECOMMENDED BATTERY RATING MINIMUM 350 AMPS COLD CRANKING AMPERAGE
CRANKCASE OIL SAE 30 70 and Below SAE 40 70 and Above
TRANSMISSION OIL DEXTRON III
CLOSED COOLING FLUID 50 WATER 50 ANTIFREEZE
CAPACITIES
CLOSED COOLING APPROXIMATELY 24 US QUARTS
CRANKCASE OIL ADD 1 QT OIL FOR ALUM PAN APPROXIMATELY 10 US QUARTS
EACH OIL FILTER USED ON ENGINE SHEET METAL PAN APPROXIMATELY 8 US QUARTS
JETPAC PAN WSINGLE FILTER 7 US QUARTS
JETPAC PAN WDUAL FILTER 8 US QUARTS
See Transmission on Page 14
C R AT ED BY MAR IN E PO W ER IN C IN AC C O R D AN C E W IT H SAE J607 PR O P SH AFT RAT IN G W ILL VAR Y AC C O R D IN G T O
D R IVE U SED
SYNT HET IC O IL MAY BE SUBSTIT UT ED
AN Y TYPE H YDR AU LIC T R AN SMISSIO N FLU ID S W H IC H MEET ALLISO N T YPE C 3
9 ENGINE X PERFORMANCE MOTORS 500X 530X
500X C arbureted 530X PFI
EN G IN E T Y PE V8
C R AN K SH AF T H OR SEPO W ER H PK W 500 373 530 395
D ISPL AC EM EN T 82L
BOR E STR OK E IN C H ES 447 X 400
C O M PR ESSIO N R AT IO 961 961
M AXIM U M R PM W ID E OPEN TH R OT T L E 5200
ID L E R P M IN F OR W AR D G EAR 700 900 R PM
F U E L P UM P PR E S SU R E 4 7 PSI 39 PSI
OIL P RE S S U R E 2000 R PM 20 60 PSI
M IN IM U M OIL P R E SSUR E ID LE 10 PSI
T H ER M OST AT 143 62 C R aw W ater C o o led
SPAR K PL U G T Y PE C h am p io n 415 R N 9Y C C h am p io n 415 R N
9Y C
SPAR K PLU G G AP 035
T IM IN G ID L E R PM 12 12
T OT AL M AX TIM IN G AD VAN C E 4000 R PM 32 N A
F IR IN G OR D ER EL EC T R IC AL SY S TEM
12 VO L T N EG AT IVE G R O U N D
AL T E RN AT OR R AT IN G 70 AM PS
R EC O M M EN D ED BAT T ER Y R AT IN G M IN IM U M 350 AM PS C O L D C R AN K IN G AM PER AG E
C R AN K C ASE OIL SAE 30 70 and Belo w SAE 40 70 an d Ab o v e
T R AN SM ISSION OIL D EXT R O N III
C L O SE C O O LIN G F L U ID 50 W AT ER 50 AN T IF R E EZ E
C AP AC IT IE S
C L O SED C O O L IN G APPR O X 24 U S Q U AR T S
C R AN K C ASE O IL AD D 1 QT OIL FOR EACH OIL FILT ER APPR O X 10 U S Q U AR T S
T R AN S M IS S ION OIL C APAC ITIES
BO R G W AR N E R 7172C SER IES 11 2 U S Q U AR T S 19L
BO R G W AR N E R 7172C SER IES 15 291 3 U S Q U AR T S 28L
BO R G W AR N E R 5000 SER IES 11 281 2 U S Q U AR T S 19L
BO R G W AR N E R VD R IVES AL L R AT IO S 4 U S Q U AR T S 38L
Z F 63A SER IES 32 U S Q U AR T S 30L
Z F 63V SER IES 42 U S Q U AR T S 40L
Z F 45D SER IES 21 U S Q U AR T S 20L
Z F 45A SER IES 32 U S Q U AR T S 30L
C R A T E D B Y MAR IN E PO W ER IN C IN ACC O R D ANC E W IT H SAE J 607 PR O P SH AF T R AT IN G W ILL VAR Y AC C O R D IN G T O D R IVE U
SE D
SYN T H ET IC O IL MAY BE SU BST IT U T ED
A NY T Y P E HY D R AULIC T R ANSM ISSIO N FLUID S W H IC H MEET ALLISO N T YPE C 3 SPEC IF IC AT IO N S
10 A WORD TO THE past twenty years has seen a revolution in the way both automotive and marine engines are built The is the advent of Electronic
Fuel Injection or EFI
Before EFI the carburetor was the most popular and easiest way of supplying fuel to the engine The fuel into the engine by using a mechanical means
of linkage throttle plates jets etc While it did an
excellent job for many years it was not efficient and it was adjustable only to a certain point with a it is much different EFI engines are operated
by a computer and sophisticated engine calibrations are critical to how much fuel the engine receives and are peculiar to a specific engine type
The sensors that feed information back to the computer are not adjustable nor can they be repaired The senors
must be engine technicians receive specialized training in the diagnosing and correcting of EFI A factory trained technician is required to properly
diagnose and repair your Marine Power EFI engine
to avoid irreparable or permanent engine damage
ENGINE problems are very difficult to attempt to solve over the telephone In most cases the trained eye of a
good marine technician is the easiest and fastest way of determining and solving a problem Contacting the
dealer distributor or the factory and trying to resolve the problem over the telephone only tends to lengthen the
time of repair
ENGINE CARE
Most engine problems can be avoided with a good engine maintenance schedule Marine engines are operating
at much higher rpms than automobile vehicles The work that a marine engine does at cruising speed is
comparable to an automobile engine going uphill in a strong headwind all the time The engine parts must work
harder and thus require more attention Oil filters sparkplug wires sparkplug distributor rotors caps can make all the difference in the world in
performance versus being towed back in
can be a major contributor to engine damage Old last season fuel loses its octane rating and does
not create the correct amount of cylinder burn This can cause DETONATION or fuel knock were the fuel will
explode violently in the cylinder The explosion in turn causes overheating or damage to the spark and valves Any engine stored for thirty 30 days or
longer needs a fuel stablizer We recommend that
STABIL be added to the fuel per the directions This will prevent the formation of in the fuel system
CRANKCASE OIL
Some engines are installed on an angle This causes the oil to flow to the back of the oil pan Consequently the
oil level on the dipstick may change It is the of the installer and the owner to determine the
correct oil dipstick reading To little as well as to much oil will cause engine damage
COLD WEATHER OR EXTENDED STORAGE
If you put your boat away for the winter or you will not be using it for an extended length of time it that a competent marine service facility be
contacted to perform the winterization or storage
THIS PAGE
LEFT BLANK
SECTION TWO
GENERAL General Informatio n
1824
Engine Compartment 18
Engine Mountin 18
Engine Be d
Sea Water Piping 18
Fuel Line s
Electrical Connection s
Exhaust Pipin 19
HydroLoc k
Water Inversion 20
Detonation or PreIgnition 20
PreStart Checklis t
Gasoline 21
Starting 21
Starting EngineEF 22
Proper Engine BreakIn 22
10 Hour Servic e
Engine Rotation 24
Propeller Information 24
11 GENERAL N OTE Before shipment each engine has been
carefully tested inspected and drained of coolant
It may be necessary to delete or add oil from the
engine and transmission for various engine
If engine is equipped with a closed
cooling system it is im perative to fill the system
with a 5050 mix of ethylene glycol base
antifreeze and clean fresh water Failure to use a
5050 mixture of antifreeze and water can result
in engine damage See Eng ine Section
ENGI NE COM PARTM ENT ENGINE BED
The engine compartment should be wellplaned to accessibility and ventilation Engines
must have air as well as fuel to operate battery should be located as close as possible to
SEA W ATER PI PI NG
the starter motor so that the battery leads can be kept
short
CAUTION
ENGI NE M OUNTI NG DO NOT operate engine without water being
supplied to raw water pump as damage to the
impeller and engine will installation is very important If the angle is too
severe over 10 degrees may require a wedge plate
under the carburetor oil and fuel problems may be The throughhull fitting and sea cock should be
placed as close to the engine as possible and be size larger than the water pump inlet
The water
pump inlet scoop should face the bow of the boat in
ENGI NE B ED an area where there are no
Obstructions could cause water turbulence and
prevent a solid stream of water from entering the sea
The engine
scoop
bed should
b e o f
The hose on the suction side of the pump must be of
hori zon t al
a type It is highly and
that a sea strainer of adequate size be between the sea cock and engine If no sea
to maintain strainer is installed periodically check the cooling
e n g i n e inlet system to
alignm ent clear debris
All of the from engine
thrust used a n d
in moving transmission oil
the boat is c o o l e r s
transferred Debris entering
to the hull through the engine bed The standard t he cooli ng
engine has support mounts that are intended to be system is one
used on engine beds arranged for 22 bolt centers of the main
Use adequate bolts for each support Make certain causes of
there is no interference on the underside of the engine the oil pan or other components located in
that area and the hull
11 GENERAL INFORMATION Continued
Marine Power requires installation of external
FUEL LI NES and internal flappers to prevent hydrolock
Hydrolock is not warrantable
IMPORTANT In repower applications inspect all
fuel lines for possible restrictions Fuel tanks should To prevent water inversion it may be
be installed below the height of the fuel system It is necessary to install 90 degree exhaust dumps
recommended that an antisiphon valve be included in adjacent to the manifold exhaust risers This type of
the fuel tank installation is usually found in boats with
exceptionally long sloping exhaust routing ie
A 38 minimum Type A1 USCG tunnel drive or negative engine installation tubing is recommended for the fuel line such as VDrives
Consult your dealer
from the tank to the engine for all 18130L 26243L
and 35057L engines All 60L and larger engines
must be minimum inner dimension It should be
adequately secured and provided with a near the engine to reduce vibration to the for the tubing should conform to current Coast
Guard or American Boating Yacht It is also recommended that older copper
fuel lines be replaced with an approved fuel line
All Marine Power EFI engines require the fuel return
line be connected only to the fuel tank
Fuel tanks should be of a size adequate with the and should be anchored securely and
vented in such a manner to conform to Coast The fuel tank filling arrangements to all safety regulations and must be
outboard The installation of an approved fuel shut off
valve at the tank is mandatory
ELECTRI CAL CONNECTI ONS
All electrical connections should conform to US
Coast Guard or American Boating Yacht EXHAUST PI PI NG
WARNING MARINE POWER does not
warranty items damaged due to hoses must be installed to prevent water
from returning to engine Exhaust hoses must have
a definite slope to the transom of not less than per
foot of length If pipe is used in the exhaust it must be separately supported so the
weight of the pipe is not carried by the outlets
11 GENERAL INFORMATION Continued
To minimize this problem Marine Power requires the
HY DR OLOCK installation of flappers at the transom and in the
exhaust hose just after the exhaust riser or elbow
Water can enter the engine cylinders through the
exhaust system Beware of these situations
DETONATI ON OR P R EI GNI TI ON
1 Following Wakes Sudden slowdowns may
cause the boat wake to flow over the transom of Detonation is most commonly known as pinging
your boat spark knock or fuel knock It is the abnormal
combustion of the fuel which causes the fuel to
2 Engine Shutdown Sudden engine shutdown explode severely within the combustion chamber
while the boat is moving may force water into
the exhaust system In a fourcycle engine normal combustion or
burning starts at the spark plug and a wave of
3 Improper Installation Refer to exhaust pipe flames move across the combustion chamber This
section An exhaust system without flappers results in an even pressure rise in the combustion
and the specified incline increases the chamber which pushes the piston downward
likelihood of water entering the engine
Detonation begins as normal combustion with the
4 Improper Hoisting Operators are sometimes sparkignited flame progressing across the
tempted to reduce hoisting time for propeller combustion chamber while applying the heat and
changes by hoisting only the boat stern Such pressure to the unburned portion of fuel Instead of
hoisting can cause residual water in the exhaust continuing to burn evenly the last portion of the fuel
system to enter engine cylinders explodes violently which in turn causes overheating
of the pistons valves and spark plugs
Water entering engine cylinders will cause the engine
to lock because water does not compress To remedy This may occur at any speed and is not often
this situation take the following steps detected serious and tragic engine damage may
1 Change engine oil filters occur
2 Remove all spark plugs
3 Remove coil wire There are many causes of detonation with the most
4 Crank engine for 15 seconds common being the use of a lowoctane gasoline
5 Replace spark plugs and reattach coil wire Detonation may also occur when using the proper
6 Start engine if there are any abnormal sounds octane gasoline if engine maintenance has been
STOP ENGINE immediately and contact your neglected
MARINE POWER dealer Poor or improper fuel Improper initial
ignition timing setting
Improper propeller selection
W ATER I NVERSI ON Engine overload such as operating twinengine
boat with only one engine
Water inversion is water that is pulled back into the Improper cooling operation resulting in and usually ends up in the piston cylinder
of the time this happens under the following Fuel starvation or vapor lock resulting
poor fuel quality lean out
Shutting off engine at high RPMs carburetor causing lean mixture
Water comes up the exhaust after a quick Operating engine that is out of proper tune
slowdown dead cylinder defective distributor cap
Long periods of idling Excessive exhaust backpressure caused by
Exhaust drop not sufficient restricted exhaust mufflers or the water is not found until the next time the
boat is used In some cases this may not be for
weeks In the case of a salt water environment this due to the 11 GENERAL INFORMATION Continued
fuel lines are possible If this type of gasoline is
P R ESTART CHECK LI ST used a complete fuel system inspection is required
prior to engine operation Repair or replace worn or
damaged parts immediately
CAUTION
DO NOT operate engine without water being STAR TI NG ENGI NE CAR B UR ETED
supplied to raw water pump as pump impeller and
engine will be damaged A fully charged battery 1214V is necessary to
crank a cold engine At lower temperatures a MARINE POWER requires that your fuel mixture is desired at startup For dealer perform a
sea trial for proper engines you may have to pump the throttle of your warrantysea trial form Failure to more than usual while
cranking the engine to registered your engine will result in warranty repairs if required Registration is
required by the Federal Boat Safety Act
CAUTION
DO NOT operate engine without water being
1 Check engine and transmission oil level supplied to raw water pump as pump impeller
and engine will be damaged
2 Check that all engine drain plugs are installed
and tightened
WARNING Gasoline vapors are highly
3 Check for proper coolant level if engine is explosive under certain conditions
equipped with optional closed cooling system
Ensure than the coolant tank cap is tight The
1 Operate bilge blower for five 5 minutes If not
cooling system must be filled with a 5050 mix of
equipped with bilge blower open engine hatch
ethylene glycol base antifreeze and clean fresh
and leave open while starting engine to remove
water See Routine Maintenance Section for
any ex plosiv e f um es f rom engine
Filling Check throttle linkage to make sure it operates
2 Place shift lever in the neutral position
freely and that it returns to the idle position
3 Pump throttle lever two 2 times to prime
5 Check transmission shift lever Refer to your
intake manifold
transmission operator manual
4 Place throttle 14 open
6 Inspect fuel and water system for leakage
5 Turn ignition switch to start position The
7 Check that all engine mounts are tight
engine should start within twenty 20 seconds
8 Check that battery is secure and all electrical
6 Run engine at 1000 RPM until it reaches
connections are tight
normal operating GASOLI NE R ECOM M ENDATI ON Raw Water Cooling Operating temperature
should be 140 165 Power recommends the use of unleaded
Closed Cooling Operating temperature of at least 87 octane to insure performance range 160 190 ADDED of
ethanol or methanol type gasolines are for use in your Marine Power effects such as but not limited to wear to internal parts or damage to flexible
11 GENERAL INFORMATION Continued
P ROP ER ENGI NE B REAK I N CAUTION
Engine dipstick level may change due to the angle
CAUTION of installation Ensure that high oil level is
properly marked accordingly
First twentyfive 25 hours vary the RPM Avoid
sustained periods of wide open throttle Some
EFI engines will not reach WOT until engine is up CAUTION
to normal operating When adding crankcase oil DO NOT OVERFILL
If crankcase is overfilled it will cause foaming or
CAUTION aeration of oil in the oil pan This will effect oil
pressure which may result in severe internal engine
If the engine is to be operated after the initial damage
breakin period near or at maximum rpms in
rough water conditions wherein the craft may 2 VOLTMETER Normal reading is 130 145
become temporarily airborne a RPM Rev volts at 2000 RPM
Limiter Device must be installed on the engine to
prevent a runaway condition which could 3 OIL PRESSURE Not less than 10 PSI at idle
seriously damage the engine or its component
parts Rev limiters are included on all EFI 4 NORMAL OPERATING TEMP
systems Raw water cooling Less than 165 degrees
Closed cooling Between 160 and 190
AT NO TIME SHOULD THE ENGINE BE
degrees
OPERATED BEYOND THE SPECIFIED
MAXIMUM RPM RATING FAILURE TO 5 IDLE RPM Normal reading is 650 800 RPM
ADHERE TO THESE in gear Note For Jetpac applications normal
WILL VOID THE TERMS OF WARRANTY reading is 8001000 RPM
To insure maximum life of your MARINE POWER 6 THROTTLE AND SHIFT CONTROLS Check
engine the following engine breakin schedule is that movement is not constrictive Verify
linkage is adjusted so that engine may reach
Wide Open Throttle WOT
First hour Perform sea trial
7 EXHAUST OIL WATER AND During the breakin period pay close SYSTEM Inspect for leaks Be sure to to the following steps
riser bolt tightness after 10 hours and every 50
hours of operation Refer to OIL LEVEL Check the oil level before each Schedule
engine start up and every eight 8 hours of
continuous operation It should be understood that
internal combustion engines will use a certain 10 HOUR SER VI CE
amount of oil during operation as a cooling and
lubricating agent especially during breakin It is very important to retighten exhaust
period Oil consumption should decrease after manifold riser bolts after 10 hours of operation
approximately 100 hours of operation Failure to do so can cause engine The
space between the FULL and
ADD marks on the dipstick represent one quart It is
not necessary to add oil unless the level is at or below
the ADD mark
11 GENERAL INFORMATION
ENGINE ROTATION PROPELLER W ARNI references used in this section are given
as if standing behind the boat looking forward WARNING MARINE POWER does not warranty
front of boat is bow items damaged due to detonation The propeller
selected should allow the engine to operate at or
rear of boat is stern
near the recommended wide open throttle RPM
right side is starboard
range with a normal load Wide Open Throttle
left side is port
RPM range is listed in Engine Section
The raw water or seawater pump is located at the
front of the engine on the crankshaft pulley can be determined by looking at the stern end WARNING Using a propeller too large will not
of the engine and observing the flywheel rotation Do allow the engine to reach its rated RPM range
not assume engine rotation by looking at the propeller which will create an overloaded condition and
rotation it may not be the same This information is possible destructive detonation that can be
critical when ordering parts for your engine harmful to the engines performance and life
Left Hand Engines CCW or Normal Hand Engines CW or Opposite Rotation PROPELLER INFORMATION
Diameter pitch or coupling of a propeller will affect
engine rpm and boat performance Configuration of
the blade also effects performance Even propellers
from different manufacturers with the same pitch and
diameter will perform Testing for a correct propeller is accomplished by
operating the boat with an average load at Wide
Open Throttle WOT rpms should be at the high end
of the specified range and checked with an accurate
tachometer This will allow the engine not to fall
below the rpm specified range under a heavy load
condition If the engine rpm is above or below the
specified range a change in the diameter andor pitch
of the propeller is required Newly installed engines
operating 100 300 RPM below wide open throttle is
usually a propeller SECTION THREE
ROUTINE MAINTENANCE
12 Routine Maintenanc 2636
How To Use This Section 26
Please Be Carefu 26
Crankcase Oil Chang e
Ambient Oil Temperature 27
Oil Filte
Starter Top Mount Only 28
Flame Arresto r
Carburetor Fuel Filte r
Changing Carburetor Fuel FilterHolley 28
Water Separating Fuel Filte r
Changing FuelWater Filte r
GForce Fuel 29
Battery Cables 29
Multiple Engine Battery 30
Alternation Belt Tensio n
Checking Belt Tension 30
Delco EST Ignition Using Timing Tool Carbureted Engine 31
Engine TuneUp 32
Raw Water Cooled Engines 32
Closed Cooling System 32
Filling Closed Cooling System 32
Extended Storage and Storage in Below Freezing Temps 33
Fogging Procedures 34
Returning Engine To Service After Extended Storage 34
13 Scheduled Maintenance By Owne 35
14 Scheduled Maintenance By Qualified Technician 36
12 ROUTINE MAINTENANCE
Performance could be sacrificed without original
HOW TO USE THI S SECTI ON Marine Power parts or parts recommended by
Marine Power A marine environment is a tough
This manual provides basic information on routine one Parts subjected to salt water can of Marine Power engines Whether the
corrode and engine failure could result is an experienced marine mechanic or a first on Marine Power Engines could also be affected if
time boat owner we strongly suggest you thoroughly other than recommended replacement parts are
read these procedures BEFORE you attempt any Make sure you are familiar with the and the methods recommended Safety is
TROUB LESHOOTI NG
our first concern If repair required is beyond please contact your dealer or other If a problem
is detected contact your Marine Power
dealer first He is trained to manual contains guidelines to convey a particular your problem and handle warranty repair
level of risk
NOTE Some of the remedies described should
DANGER HAZARDS THAT WILL RESULT IN be attempted by qualified personnel
SEVERE INJURY OR DEATH
WARNING HAZARDS THAT COULD RESULT
IN SEVERE INJURY OR DEATH Please refer to the Guide section
CAUTION HAZARDS WHICH COULD RESULT Remember that a problem is not normally caused
IN MINOR INJURY OR PROPERTY DAMAGE only by one part but by the relation of one part with
other parts This list cannot give all possible
problems and corrections The serviceman must
P LEASE B E CAR EFUL find the problem and its source then make the
necessary repairs A normal ignition and fuel system components on schedule has been prepared to help the Power engines comply
with US Coast Guard care for his or her new Rules and Regulations to minimize risks of fire
and explosion Use of replacement electrical ignition Following this schedule will help the owner get the
and fuel components which do not comply with these most troublefree operation of his new engine
rules and regulations could result in a fire or explosion
and must be avoided The electrical and ignition CR ANK CASE OI L CHAN GE
system is capable of violent electrical shock the battery cables when performing any
work where the cables could touch IMPORTANT Start engine and operate until
normal temperature is reached Warm oil flows
Take care to properly install and tighten all components more freely carrying away more impurities Remove
when servicing the electrical ignition and fuel systems the oil into a suitable container Some oil will remain
If the installation is not correct sparks could ignite fuel in the pan and engine It is a small quantity and will
vapors from the fuel system make the new oil appear used
If you are doing repair work around the intake or WARNING The Federal Water Pollution openings always protect those openings
Act prohibits the discharge of oil or oily waste into
against foreign matter entering the cylinders or upon the navigable waters and contiguous
zone of the United States if such must be taken to use exact replacement parts causes a film upon or discoloration of the
Damage could result if mismatched If a grade 5 hex surface of the water or causes an emulsion or
head bolt is removed the same grade 5 hex head bolt sludge beneath the surface of the water
must be replaced If you cannot reuse the same bolt Violators are subject to a penalty of 5000
do not 12 ROUTINE MAINTENANCE Continued
NOTE For All High Performance Engines Carbureted
CAUTION and MPI Please refer to Maintenance Schedule for
specific intervals to check engine crankcase oil This
DO NOT overfill crankcase with oil Agitation or type of engine will normally use a certain amount of oil to
splashing of oil may cause it to become aerated cool and lubricate during operation therefore oil
which will effect oil pressure and may result in consumption will be higher These engines are equipped
internal engine damage from lack of lubrication with forged aluminum pistons designed to withstand
Oil being splashed by reciprocating engine parts higher horsepower output Since the pistons are forged
onto the walls of the cylinder in greater quantity they require increased piston to cylinder bore clearance
than the rings can control will subsequently be to accomodate for higher causing
drawn into the combustion chamber and burned additional oil consumption during wide open throttle
operation It is not uncommon for these types of high
Continuous operation under these conditions can
performance engines to use up to one 1 quart of oil per
cause carbon to form on chamber surfaces which 15 hours of during this type of operation
will adversely affect engine performance and
may lead to premature engine repair
OI L FI LTER S
Start engine and run for 5 minutes to circulate Inspect entire engine for leakage Shut NOTE Lay a towel or catch basin under the filters
off engine and wait 5 minutes for oil to drain back into to catch any spilled oil
pan Check level with dipstick Add oil to proper level
if needed 1 Unscrew old filter by using a oil filter wrench
and turn counter clockwise Once Power does not recommend the use of clean mounting base Be sure old gasket nondetergent type
oils Oils that removed from mounting base
contain solid additives or low quality oils other
than 20W40 or 20W50 are also not 2 Apply thin film of oil do not use grease to
gasket Be sure gasket is seated properly in
base of filter
The following is a guideline for crankcase oil selection
for ambient terperatures A new oil filter should also 3 Hand tighten filter plus turn after gasket
be included with your oil change contacts mounting base Use a filter wrench is
necessary Do not over tighten
4 Check to see that oil shows FULL on
AM B I ENT OI L TEM P ER ATUR E
dipstick Start engine Run for approximately 5
minutes and inspect for leaks
5 Shut off engine and wait 5 minutes for oil to
drain back into pan Check level with dipstick
Add oil to proper level if needed
ALWAYS CONTACT YOUR NEAREST MARINE
POWER SERVICING DEALER IF YOU HAVE A
PROBLEM
12 ROUTINE MAINTENANCE Continued
STAR TER TOP M OUN T ON LY
Starters are notorious for problems due to moisture
and Marine Power uses a topmounted rear
entry starter on most Sportpac and Jetpac models
that reduces starter problems and is more lubricating oil on the starter pinion and shaft
1 Remove rubber plug A in flywheel housing
2 Spray lubrication oil through hole and replace
rubber plug
CA R B UR ETOR FUEL FI LTER
WARNING Do not perform this task while
engine is hot Gasoline vapors are highly
explosive under certain conditions
IMPORTANT Lay an absorbent towel under the fuel
line connection at the carburetor to absorb fuel
Dispose of properly
CHAN GI N G CAR B UR ETOR FUEL FI LTER
FLAM E AR R ESTOR
Clean the flame arrestor Remove wingnut E from top of flame arrestor
cover Remove weather cover B Remove
breather hose from flame arrestor Remove
flame arrestor C from engine
2 Clean with a suitable solvent and blow dry
3 Reverse steps to 12 ROUTINE MAINTENANCE Continued
W ATER SEP AR ATI NG FUEL FI LTER B ATTERY CAB Lay an absorbent towel under the fuel line WARNING Do not recharge a
weak battery in
connection at the carburetor to absorb fuel Dispose of
a boat Remove and recharge in a area away from fuel vapors sparks or flames
1 Unscrew old filter by using a oil filter wrench and
Electrical systems in a marine environment require
turning Once removed clean
periodic attention Continued use of a weak battery or
mounting base
dirty terminals can cause solenoid or starter problems
Clean battery and terminals every 100 hours Note the
2 For EFI equipped engines fill 34 full with clean
condition of your battery cables When reconnecting
fresh gasoline before reinstalling filter
battery cables make sure that the RED cable is on the
terminal and the BLACK cable is on the
3 Hand tighten plus turn new filter by turning
terminal Black is ground
filter clockwise after gasket contacts mounting
base Use a oil filter wrench if necessary DO
NOT Start engine and inspect for leaks
CHANGI NG FUEL W ATER FI LTER
GFOR CE FUEL SY STEM
1 Position catch basin under filter
2 Remove drain plug
3 Unscrew cannister bowl
4 Pull element down from pump
5 Push new element Part 425611 on pump until
click is felt
6 Replace oring included with filter
7 Reinstall cannister bowl on unitsnug tight only
8 Two 10second key ups should prime system
12 ROUTINE MAINTENANCE Continued
and adjust tension by pivoting alternator When
M ULTI P LE EN GI N E B ATTER Y
correct tension is achieved tighten alternator
P R ECAUTI ONS EFI
mounting screw
The alternator is designed to charge the battery that Serpentine belt system maintains tension with a
supplies electrical power to the engine When
springloaded tensioner Normally no
batteries for two separate engines are connected will supply all the charging current for both maintenance is In normal instances the other will
not be required to supply any charging
CHECK I NG B ELT TENSI Electronic Control Module ECM requires a
steady stable voltage source In multiple an electrical onboard device may cause a
sudden drain of voltage at the engines battery The
voltage may go below the ECMs minimum of nine 9 volts and the idle alternator on the
other engine may now start charging This could
cause a voltage spike in the engines In these cases the ECM could shut off
When the voltage returns to the required range
the ECM will reset itself The engine should
begin to run normally However this ECM shut
down occurs so rapidly that the engine just
appears to have an ignition miss In packages each engine must be
connected to its own battery This provides the
required voltage source for the ECM
In these applications where battery switches are
used it is important that each switch be
positioned to allow each engine to run off its battery DO NOT run engines with the
battery switches in BOTH or ALL will allow the other engines battery to be
used in case of emergency to start the engine
with the dead battery
ALTERNATOR B ELT TENSI ON
WARNING Make sure ignition key is removed and
engine is not running before inspecting belts
To check belt tension press down on belt
midway between the alternator pulley and pump pulley The belt should inch If belt depresses more than
onehalf inch loosen alternator mounting 12 ROUTINE MAINTENANCE Continued
7 Tighten distributor clamp to hold in position
DELCO EST IGNITION when initial timing is obtained
8 Recheck timing
USI NG THE TI M I NG TOOL Carbureted
Engine 9 Remove the timing tool from EFI Engines Refer to EFI Section 10
Check total timing at 4000 RPM See Engine
Section
The timing tool is used in setting the initial engine
timing on MARINE POWER carbureted engines This 11 Disconnect and remove the timing bypasses the electronic spark timing of
the engine and allows the initial timing to be adjusted
by rotating the distributor Use the become familiar with entire ignition timing marks are located on the cover A saw slot on the balancer at TDC
Top Dead Center Adjust as follows
1 Connect a timing light to the number one 1
spark plug wire Connect the timing light power
lead to a 12 volt power source DO NOT
CONNECT TO 12 VOLTS ON Start engine and allow to warm to operating
temperature Bring engine to idle 650800
3 WHILE ENGINE IS RUNNING install the timing
tool supplied with your engine into the terminal
connector on the Loosen distributor clamp just enough to rotate
distributor in place
Note An adjustable timing light is required to set
initial and total timing
5 Secure the bare wire and of the timing tool to
battery positive voltage the most
convenient location of this voltage is on the
cranking motor solenoid If desired a suitable
clip such as an alligator clip may be
permanently attached to the bare wire end of the
timing tool to hold it in place
6 Rotate distributor to set mechanical timing
REFER TO THE APPROPRIATE ENGINE
SECTION OF THIS
MANUAL FOR CORRECT TOTAL AND
INITIAL TIMING FOR YOUR ENGINE
12 ROUTINE MAINTENANCE Continued
The cooling system does require certain preventative
ENGI NE TUNEUP S maintenance to keep it in optimum operating
to Maintenance Chart for tuneup schedules
Zinc Anode Your cooling system is equipped with a
1 Disconnect battery terminals zinc anode that is approximately 2 long This anode
should be inspected for deterioration after the first 10
2 Remove distributor cap and inspect for corrosion hours of operation Inspect again after 50 hours of
on the electrodes cracks and wear Replace if operation and every 50 hours thereafter
necessary
Recovery Bottle The plastic recovery bottle is
3 Spray interior of distributor with a moisture attached to the heat exchanger tank on most
displacing product models and fills with coolant during operation when
the internal water temperature is higher If necessary
4 Reinstall rotor and cap and tighten add coolant only when engine is cold
5 Replace spark plugs Check gap Refer to Filler Neck and Pressure Cap DO NOT remove
Engine Specification Section pressure cap when engine is HOT If coolant is low
add the proper mixture 50 water50 antifreeze to
6 Check spark plug wires for deterioration andor the top of the filler neck located on the heat
damage Replace if necessary to assure exchanger tank If coolant is consistently low
maximum running efficiency additional inspection for leaks in the cooling system
may be required
7 Spray carburetor and control linkages with a light
oil product
8 Inspect pump impeller and alternator belt
9 Refer to timing procedures to set timing
10 Check zinc anodes in fresh water cooling tank
seasonally if equipped Replace if more than
half is eroded
R AW W ATER COOLED ENGI NES
Raw water cooled engines are cooled by pumping FILLING CLOSED COOLING water from water inlet seacock or
stern drive leg in to engine and out through exhausts SAFETY WARNING Do not remove pressure
This water must be drained for freezer protection cap when engine is hot Coolant is under
See Raw Water Cooling Diagram for your specific pressure and may be forced out causing
injury After engine is cooled remove cap slowly
to allow pressure to escape
CLOSED COOLI NG SY STEM
IMPORTANT The closed cooling system must
The closed cooling system is designed to provide remain filled yearround with the proper life to your new Marine Power engine Your
of 50 water to assure will operate at a different temperature range of system during the lowest exposed
from a raw water cooled engine Please refer to the engine specification page for 12 ROUTINE MAINTENANCE CLOSED COOLING SYSTEM Continued
CAUTION
Insure that all drain plugs are installed and Do not operate engine without water being
tightened supplied to the sea water pump as pump impeller
Fill heat exchanger tank with 5050 and engine will be damaged
mixture After initial fill start
engine and continue filling heat exhanger Engine
must be purged of air by bleeding system Engines 1 Shut down engine and change engine oil and
may be bled in a variety of ways however the filters Refer to Normal Maintenance Section
follow bleed points are suggested
30L181 Side Mount Full System Heat V6V8 blocks must be drained on both sides Drain
exchanger cap is sufficient plug locations are as follows
43L57L Front Mount Full System Heat 30L181 Single plug on port side of lower
exchanger cap is sufficient block
43L57L Rear Mount Full System Carbureted Plug on
Disconnect hose from top of circulating water lower center portion of block on each side
pump 43L57L EFI Knock sensor is located in port
60L Side Mount Full System Air bleed on block drain Sensor must be removed for
starboard exhaust manifold draining and retorqued to 22 ftlb When re
81L Side Mount Full System Open pet installed
cock on water tube crossover and remove 60L Plug on starboard side is vertically
18 plug on top of heat exchanger at rear of located on lower block Use 8mm Allen
engine wrench to remove Plug on port side is parallel
74L82L Front Mount Full System Heat to lower block surface Use 17mm Allen
exchanger cap is sufficient wrench to remove
74L82L Rear Mount Full System 81L Plug on each side of lower center block
Disconnect hose from top of circulating water Use 8mm Allen wrench to remove
pump
Bleeds should be left open until all sign of air Reinstall hose on circulating pump after system
bubbles disappear Engines bled at cap must be has drained completely Coat all plug threads with
ran 2000 rpm with cap ope to bleed all air 60L sealant and reinstall into proper locations
and 81L engines are difficult to purge Use Remove engine oil and transmission cooler drain
caution thermostat must open to remove all air plugs
this process may take ten 10 minutes Continue Remove hoses from sea water pump if applicable
filling the heat exchanger after bleeds are closed Remove circulating pump hose and all exhaust
After themostat has opened and heat exchanger is manifold drain plugs Drain engine completely
topped off install heat exchanger cap Fill plastic
reservoir full 3 Any engine stored for thirty 30 days or longer
Check for leaks after finished fill procedures needs a fuel stabilizer We recommend that
STABIL be added to the fuel per the manu
facturers directions This will prevent the
formation of harmful varnish in the fuel system
EXTENDED STOR AGE AND STOR AGE I N
B ELOW FR EEZI NG TEM P ERATUR ES 4 Fog engine Refer to Fogging 5
Reconnect suction hose to sea water inlet
RAW WATER COOLED ENGINES See Raw Water Cooling Diagram for your engine
WARNING These operations should be
CAUTION
performed only by qualified marine service
personnel Do not use 100 water or antifreeze as engine
coolant Overheating and engine damage will
Note Raw water cooling requires no filling result
12 ROUTINE MAINTENANCE COOLING ENGINES 1 Check that all engine drain plugs are installed and
seacock on water inlet is open Check coolant
1 Follow raw water drawing procedure except for the levels
following
Draining manifolds are not necessary unless 2 Check all hoses to make sure they are properly
closed system is half system type as on connected and clamps are tightened
5057V EL models
Engine block does not need draining 3 Inspect bilge area and around engine for nesting
Circulating water pump hose does not need to creatures signs of leakage or physical damage
be removed
2 Remove end caps on heat exchanger Inspect for 4 Clean battery cables and install a fully charged
debris and trapped water battery Attach red wire to positive terminal
3 Refill closed cooling system according to and black wire to negative terminal It is
instructions in Filling Closed Cooling System recommended that a battery terminal
section spray be use to coat terminal 5 After
engine is started monitor gauges to insure
FOGGI NG P R OCEDUR ES engine is operating in normal operating
procedure necessary for carbureted models
only 6 After engine has reached normal operating
temperature inspect engine for leaks such as fuel
1 Remove flame arrestor cover and flame arrestor exhaust water and oil
2 Start engine and run at 1500 to 2000 RPM
3 Pour approximately one 1 cup of rust preventive
oil or if not available SAE 20W motor oil into
CAUTION
Do not pour an excessive amount of oil into the
carburetor at one time This can cause engine to
stall andor create a hydraulic lock condition in a
cylinder resulting in engine damage
4 Turn ignition switch off
5 Clean flame arrestor and reinstall on engine with
cover
6 Cover complete carburetor assembly with plastic
bag to prevent moisture from entering carburetor
during storage
R ETUR NI NG ENGI NE TO SERVI CE AFTER
EXTENDED STOR AGE
If you followed the storage procedure the new time should be minimal Please do the
following before attempting to start your 13 SCHEDULED MAINTENANCE BY OWNER
ENG INE AFT ER FIRST EVER Y 50 EVER Y 100
SERVICE ST ART UP 10 HOUR S OF HOUR S OF HOUR S OF
EAC H DAY OPER AT ION OPER AT ION OPER AT ION
CHECK ENGINE OIL LEVEL U U
INSPECT FUEL LINES AND CONNECTIONS
FOR LEAKS U U
CHECK COOLANT LEVEL IN TANK
IF EQUIPPED WITH CLOSED COOLING U U
INSPECT AND CLEAN SEA STRAINER
IF EQUIPPED U U
INSPECT ENTIRE POWER PACKAGE FOR LEAKS
WATER FUEL OIL EXHAUST ETC U U U
INSPECT BELTS FOR TENSION AND WEAR U U U
INSPECT BATTERY
TERMINALS AND FLUID LEVELS U U U
CHECK BATTERY CONNECTION TO ENGINE U U U
TOUCH UP EXTERIOR SURFACE WITH
MARINE POWER PAINT U U U
INSPECT ZINC ANODES IN HEAT EXCHANGER
FOR DETERIORATION IF EQUIPPED WITH U U U
CLOSED COOLING
CHECK POWER STEERING FLUID IF EQUIPPED U
CHECK TRANSMISSION FLUID LEVEL U U U
LUBRICATE STARTER PINION AND SHAFT U U
ENGINE STARTUP EACH DAY AND ONCE EVERY EIGHT 8 HOURS OF
35
14 SCHEDULE MAINTENANCE BY QUALIFIED TECHNICIAN
AFT ER FIRST EVER Y 50 EVER Y 100 AT LEAST
SERVICE 10 HOUR S OF HOUR S OF HOUR S OF ONC E EAC H
OPER AT ION OPER AT ION OPER AT ION Y EAR
CHANGE ENGINE OIL AND FILTERS U U U
CHANGE FILTER ON FUELWATER SEPARATOR U U
CHECK ENGINE MOUNTS TIGHTNESS U U U
CHECK RISER AND MANIFOLD
BOLTS FOR TIGHTNESS U U U U
CHECK FOR LOOSE DAMAGED OR
MISSING ENGINE PARTS U U
CHECK WIRE HARNESS PLUGS FOR
CORROSION AND CONNECTIONS U U
INSPECT DISTRIBUTOR FOR
CRACKS OR DETERIORATION U U
CHECK CONDITION OF SPARK PLUGS
REPLACE IF NECESSARY U U
INSPECT HOSES FOR DETERIORATION U U
REPLACE IMPELLER IN SEAWATER PUMP U U
CHECK PROPELLER AND
SHAFT ALIGNMENT U
CHECK AND ADJUST IGNITION TIMING
Carbureted Engine Only U
CHECK AND ADJUST CARBURETOR U
CLEAN AND INSPECT FLAME ARRESTOR AND
CRANK CASE VENT HOSE U U
CLEAN AND INSPECT CARBURETOR FILTER U U
CHANGE TRANSMISSION FLUID U
CHANGE COOLANT IF EQUIPPED WITH
CLOSED COOLING U
CLEAN SEAWATER SECTION OF
HEAT EXCHANGER U
SECTION FOUR
ENGINE DIAGRAMS
15 Coolant Flow Diagram Raw Water Cooling 181 38
16 Coolant Flow Diagram Raw Water Cooling V6V8 39
17 Coolant Flow Diagram Closed Cooling 181 40
18 Coolant Flow Diagram Closed Cooling Front Mount V6V8 41
19 Coolant Flow Diagram Closed Cooling Rear Mount 42
20 Primary Engine Wiring Harness Fuel Pump 43
21 Shift Assist Wiring Diagram Carbureted Merc Early 44
22 TBI Shift Interrupt Wiring Diagram 44
23 Initial Timing Jumper Wiring Diagram 45
24 Shift Interrupt OMC
25 EFI Primary Engine Wiring Harness 46
26 EFI Secondary Engine Wiring Harness 47
27 Engine Instrument Panel Wiring 48
15 COOLANT FLOW DIAGRAM RAW WATER COOLING SYSTEM COOLANT FLOW DIAGRAM CLOSED COOLING FRONT MOUNT 181
26 EFI SECONDARY WIRING HARNESS
SECTION FIVE
GUIDE
28 Engine Will Not Turn 50
Engine Cranks But Will Not Start 50
Engine Starts and Stops Carbureted 50
Engine Starts and Stops 50
Engine Runs Poorly At Idle and 51
Engine Runs Poorly At High RPM 51
High Speed Miss 51
Fuel System Ric 52
Fuel System Lean 52
Poor Fuel Economy 52
Oil Pressure 52
Oil Pressure 53
Excessive Oil 53
Engine Overheating 53
Water In Engine Cylinder or Bas 54
29 Excessive Oil Consumption Chart 55
30 Warranty Registration Transfer Form 56
SERVICING DEALERS
Servicing Dealers 57
28 GUIDE
The following 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 Will Not Turn Over
POSSIBLE CAUSE REMEDY
Low Battery or Bad Connection Check Charge Replace Requires 12 14 Volts
Faulty Battery Cable
Trip Circuit Breaker
Faulty Neutral Switch
Bad Starter Solenoid or Motor
Faulty Fuel Pump
Shift control in Gear
Faulty Relay Solenoid
Hydro Lock Remove spark plug look for water in the Cranks But Will Not Start
POSSIBLE CAUSE REMEDY
Faulty Fuel Pump Check Charge Replace Requires 12 14 Volts
Blown Fuel Pump Fuse
Faulty Oil Pressure Switch Replace
Insufficient Fuel Supply Check Fuel Supply Shut Off Valve Check Fuel Filter
Insufficient Cranking RPMs Check Battery Voltage
Check Distributor Cap Rotor Replace
Fouled Plugs Replace
Engine Timing Retime
Correct Firing Order Check Correct
Low Compression
Bad Old Fuel
Fouled Carburetor
ENSURE A TUNE UP IS DONE EVERY 100 HOURS OR EVERY Starts and Stops Carbureted
POSSIBLE CAUSE REMEDY
Cold Engine When engine starts move throttle to a higher rpm Carburetor Only
Engine Idle Too Slow Adjust Choke Carbureted Engine Only
Faulty Key Switch
Faulty Carburetor Check in line filter Check carburetor filter
Internal Failure
Starts and Stops EFI
POSSIBLE CAUSE REMEDY
Faulty Fuel Pump Operation Verify fuel supply and return not reversed Verify fuel supply and
Vapor Lock pickup not sucking air
Insufficient Fuel GUIDE
Engine Runs Poorly At Idle and CAUSE Firing Order Check Adjust Ignition Timing
Choke Spark Carburetor Check for sticking or burnt valve or broken valve Cylinder Head Surge Stall Lack Power Carburetor float
adjustment Power Piston Leaking Runs Poorly At High RPM
POSSIBLE CAUSE REMEDY
Low Grade or Old Fuel Check Clean Timing
In Need of a Coil
Engine Fuel Tank AntiSiphon Exhaust
Low PERFORMANCE CAN BE GREATLY AFFECTED BY BOAT HULL AND PROP Speed Miss
POSSIBLE CAUSE REMEDY
Water in fuel Inspect Clean fuel fuel supply
Spark plug or wires
Faulty distributor Module
Loose ignition coil
Ignition timing Total fuel pump
Loose electrical connection at 51
28 GUIDE
Fuel System Rich
POSSIBLE CAUSE REMEDY
Dirty Clogged Flame Arrester Check Clean Float Gasket Line Not Directed Back System Lean
POSSIBLE CAUSE REMEDY
Empty Fuel Tank
Vapor choke Stuck open adjust
Poor Fuel CAUSE REMEDY
Boat Hull Dirty Clean Check Prop Size or Flame Arrester
Tune up
Low Engine Running Too Hot or Fuel Grade
Boat Spark Plug or Gap
Initial or Advanced Timing Wrong
Plugged or Restricted Exhaust
Oil Pressure Low
POSSIBLE CAUSE REMEDY
Low oil level in crankcase Refer to owner manual for correct oil oil in crankcase Remove excess oil Refer to owner manual for
correct oil oil gauge readings Contact dealer to perform a mechanical oil pressure Dipstick
Oil line position and oil viscosity or diluted
Oil Pump Bearing Clearance Rod Cam or Main oil pressure as low as of 5 pounds at idle is acceptable At 2000 rpm 30 pounds is 28 GUIDE
Oil Pressure High
POSSIBLE CAUSE REMEDY
Oil too thick Wrong Viscosity Change oil
Erroneous oil gauge readings Contact dealer to perform a mechanical oil pressure check
Clogged or restricted oil passage Contact dealer
Oil valve relief valve stuck closed Contact Oil Consumption
POSSIBLE CAUSE REMEDY
External Leak Clean Check Adjust
Excessive oil in crankcase
Oil Fuel dilution
Extended excessive RPMs
Incorrect oil viscosity
Incorrect dipstick
Excessive oil temperature
Defective oil cooler
Remote oil lines installed wrong
Engine breather tubes blocked
Defective piston rings
Defective Cylinders
Excessive bearing Clearance
The amount of oil used is greatly dependent upon engine speed Oil usage will be greater at higher Overheating
VERIFY IF ENGINE IS ACTUALLY POSSIBLE CAUSE REMEDY
Clogged seawater intake Clear intake Ensure that all hoses after the intake are clear
Clogged seawater strainer
Improperly installed strainer
Loose hose connections Tighten hose connections
Seawater hose kinked or collapsed
Water turbulence under boat
Defective thermostat
Seawater pump impeller worn
Obstruction in cooling system Replace seasonally
Engine circulating pump defective
Low coolant level
Antifreeze not properly mixed
Heat exchanger core plugged
Mix to a 50 50 ratio
28 GUIDE
Engine Overheating IF ENGINE IS ACTUALLY CAUSE REMEDY
Water hoses reversed Mix to a 50 50 ratio
Exhaust riser cooler blocked
Air leak in hose Riser should be changed every three to four circulating pump belt
Head gasket failure See In Engine Cylinder or Base
POSSIBLE CAUSE error See Boaters Beware REMOVE water from engine restricted or blocked
Repair or Replace REMOVE water from engine and exhaust too low in
boat Redesign add riser spacers REMOVE water from engine exhaust riser gasket Contact dealer REMOVE water
from engine exhaust manifold or
riser Contact dealer REMOVE water from engine head gasket leak Contact dealer REMOVE
water from engine block or cylinder head Contact dealer REMOVE water from engine manifold gasket Contact
dealer REMOVE water from engine engine rotation Contact dealer REMOVE water from engine water by removing spark
plugs and turning the engine over by hand Once water is removed spray cylinder with
Marvel Mystery Oil or two cycle engine oil Drain all the oil and change the oil filters 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 EXCESSIVE OIL CONSUMPTION CHART
CAUSE Oil Consumption One quart of oil consumed within 515 hours of wideopen
throttle operation is normal
Oil Level Too High
Oil Leak Clean bilge put clean white towel on bilge floor and
run engine to locate oil leaks
Oil Too Thin Oil diluted or wrong Head Drain Holes Plugged Oil will flood valve Valve Seals
Leaking Intake Manifold Gasket
Worn Valve Guides or Valve Piston Rings Worn stuck glazed scuffed improperly installed
ring grooves worn improper breakin Wrong end
Cylinders Scored tapered glazed out of round Excessive
piston to cylinder clearance cracked Bearing Oil Cooler if equipped Crack in cooler tubes
WARRANTY REGISTRATION TRANSFER
g PLEASE COMPLETE THIS FORM WHEN ENGINE OWNERSHIP HAS BEEN TRANSFERRED g
TRANSFER REGISTRATION TO
DAT E OF T RANSFER
M M D D Y Y
ENG INE SER IAL ENG INE SER IAL IF DUAL APPLIC AT ION
LAST NAM E FIRST NAM E M
ADDRESS
CITY ST ZIP
NEW OW NERS PHONE NU M BER
A C PH ON E
PLEASE ENCLOSE CHECK OR MONEY ORDER IN THE AMOUNT OF 5000 PER ENGINE TO YOU MAY PAY BY CREDIT CARD COMPLETE THE INFORMATION BELOW
VISA Number Exp Date As It Appears On the Credit Card completed form to Warranty Registration Transfer
Marine Power
17506 Marine Power Industrial Park
Ponchatoula LA 70454
Your application will be processed and a new warranty card will be sent in approximately three 3
weeks from receipt of this transfer SERVICING DEALERS
SERVICING
If You Are Unable to Locate a
Independent Servicing Dealer
Please Contact a Marine Power
Distributor Closest to You for
Further 57
SERVICE AND MAINTENANCE RECORD
OPERATING
DATE PERFORMED PERFORMED BY

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.