Tuesday, September17, 2019 L-36.com

'maine Power Owners Manual'



Note:

This is the new page for displaying documents. It allows documents to display on devices without pdf viewers specifically mobile devices, a new Google requirement. Note also that some documents have blank pages. Just click on "Next Page" if that happens.
Previous Page    Next Page Go to page number Note: Page number may not agree with index page numbers


Previous Page    Next Page
Go to page number
Note: Page number may not agree with index page numbers

PDF to Text.

   Engine
   Owner's
   Manual

         I N CLU DES


   Routine Maintenance
Troubleshooting Guidelines
 Electronic Fuel Injection
                                                  SECTION ONE


                       OWNERS OPERATION MANUAL
                                                                                                                    Pages
         1.  General Emissions Coverag.e             ................................................................. 2-3
         2.  Carbon Monoxide Exposur.e             ...................................................................    3
         3.  Introductio.n
                         .............................................................................................    4
         4.  Engine Identificatio    ..n
                                       ...............................................................................    4
         5.  Emissions Control Information            ................................................................    4
         6.  Warranty Registration/Sea Trial Informatio.                   n..........................................    4
         7.  EFI Introduction and Descriptio.            n............................................................    5
         8.  Marine Power Domestic Distributor.                s......................................................    6
         9.  Engine Specification       .s
                                         ............................................................................. 7-14
                  3.0L/181 CI.    D...................................................................................    7
                  4.3L/262 CI.    D...................................................................................    8
                  5.7L/350 CI.    D...................................................................................    9
                  6.0L/364 CI.    D................................................................................... 10
                  7.4L/454 CI.    D................................................................................... 11
                  8.1L/495 CI.    D................................................................................... 12
                  8.2L/502 CI.    D................................................................................... 13
                  500X/530    .X
                               ....................................................................................... 14
         10. A Word To The Do-It-Yourselfe              ..r
                                                          ............................................................ 15




                                                           Copyright 1994
                                                           Revised 06/03

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.

0
                                             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 State's 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 emission-related 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 2003-2008 spark- ignition inboard engines, select emission control parts from m odel year 2003-2008 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 NER'S W ARR ANT Y RESPONSIBILIT IES:

           As the inboard engine owner, you are responsible for the performance of the required maintenance listed in your owner's 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 modifications.

           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 certification.

2.     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 t
       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 Power's warranty obligations.

11.    MAR IN E PO W ER , distributor, or dealer must be advised of any warranty related problem prior to the expiration of the warranty.

12.    T his W arranty w ill not apply to:



                                                                                                                                                                      1
          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.

          ˇ    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 property.

13.       Add-on or modified parts, as defined in C C R , section 1900 (b)(1) and (b)(10), T itle 13, that are not exempted by the Air R esources Board will not be
          used. T he use of any non-exempted add-on 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 non-exempted add-on 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 (and/or pressure regulator or fuel injection system )
               2) C old start enrichment system
               3) Intake valve(s)
          B) Air Induction System
               1) Intake m anifold
               2) Air Filter
          C ) Ignition System
               1) Spark Plugs
               2) Electronic ignition system
               3) Spark advance/retard system
               4) Ignition coil and/or 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 and/or 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 and/or consequential damages are excluded from this W arranty. Implied warranties are limited to the life of this W arranty. All implied
          warranties including merchantability, 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 you.

19.       MAR IN E PO W ER reserves the right to change or improve design of any product previously assembled without notice and without obligation.

20.       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. Any/All 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.
                                                                                                                                                          W002-0300
R EV 04


2
 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, unconsciousness or death.

Carbon 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. Wind
direction, 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 technician.

Adequate air circulation in all areas of your boat are necessary in order to prevent build-up of carbon monoxide.
Please contact your boat manufacturer if you have questions regarding these hazards. For more information
regarding safe boating practices, and/or carbon monoxide poisoning on recreational boats, contact the following:

National Marine Manufacturers Association                           United States Coast Guard
200 East Randolph Drive, Suite 5100                                 Office of Boating Safety
Chicago, IL 60601-6528                                              CG Headquarters G-OPB-3
312.946.6200                                                        2100 Second Street SW
www.nmma.org                                                        Washington, DC 20593
                                                                            202.267.0984
American Boat & Yacht Council, Inc.                                 www.uscgboating.org
3069 Solomon's Island Road
Edgewater, MD 21037-1416
410.956.1050
www.abyc.com




                                                                                                                  3
 3. INTRODUCTION

The 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 MANUAL
THOROUGHLY AND COMPLETELY before attempting to operate your MARINE POWER engine. Become familiar with the
components and the maintenance schedules. If there is anything you do not completely understand contact your nearest
MARINE POWER dealer or distributor.
                                      This manual contains five (5) sections:
                      Section   ONE            Owner's 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 roubleshooting G uide                             Page   49



 4. 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.




 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 06.0 100          ENG INE         5.7L
                                             FUEL: UNLEAD                   DISP:           04/2003
                                    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 06.0 100          ENG INE         6.0L
                                             FUEL: UNLEAD                   DISP:           04/2003
                                    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 INFORMATION

T he Federal Boat Safety Act of 1971 requires that registration of marine products sold in the United States be maintained by the manufacturer
and 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 ION/SE 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. NON-COM PLIANCE M AY VOID ALL W ARR ANT IES. Please read the Limited W arranty
document 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 dealer
directly for any required w arranty repairs.




4
 7. EFI INTRODUCTION AND DESCRIPTION

                                                                  Another feature of EFI is the ability to develop
 W HAT IT IS....                                                  "calibrations" for the ECM which are specific to each
                                                                  application. For example EFI installed in a inboard ski
Electronic 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 develop
applies to any fuel delivery system which uses a computer         maximum power and efficiency for each application.9
to 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 fueled.
designed to flow air only. PFI systems are slightly more
efficient 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, RPM's 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 RPM's 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
                                                                  application.
The Engine Control Module (ECM) refers to the computer
which 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 it's output wires to the various         To reduce the chance of personal injury and/o r property
items which it controls.                                          dam age, the follow ing instructions m ust be carefully observed:

Typical inputs which the ECM uses are RPM, throttle                    Proper service and repair are important to the safety
position, 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 described
electronic 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 unit
injectors are very precise in their ability to deliver fuel and    be repaired or serviced except by an authorized
maintain their accuracy over the entire life span of the           Marine Power EFI trained technician for warranty
engine.                                                            service. Prior authorization from area distributor is
                                                                   required.


                                                                                                                                      5
 8. MARINE POWER DOMESTIC DISTRIBUTORS


Florida, Georgia, South Carolina, North Carolina,
Virginia, W est Virginia                            Ark ansas, Ok lahom a, North M ississippi
JERRY'S MARINE SERVICE                              SOUTHERN MARINE SUPPLY
100 SW 16th Street                                  6600 Murray Street, Suite 1
Fort Lauderdale, FL 33315                           Little Rock, AR 72209
(954) 525-0311 ˇ (800) 432-2231                     (501) 562-5008 ˇ (501) 562-5014
www.jerrysmarine.com                                Email: southern1@sbcglobal.net

JERRY'S MARINE SERVICE                              Louisiana , M ississippi, Alabam a, Florida
3601-B Meeting Street Road                          P anhandle
Charleston, SC 29405                                COMMERCIAL MARINE, INC.
(843) 554-3732 ˇ (800) 788-2231                     5401 Paris Road
                                                    P.O. Box 16
N ortheastern United States                         Chalmette, LA 70044-0016
JERRY'S MARINE SERVICE OF NEW JERSEY                (504) 271-7201
780 Vassar Avenue                                   www.commericalmarine.com
Lakewood, NJ 08701
(908) 901-8404 ˇ (888) 244-4735                     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,    P.O. Box 19100
N ebrask a                                          New Orleans, LA 70179
MARYSVILLE MARINE DISTRIBUTORS                      (504) 488-5731 ˇ (800) 347-4464
1551 Michigan Avenue
P.O. Box 126                                        N orthern California
Marysville, MI 48040                                SEA POWER MARINE
(810) 364-7653 ˇ (800) 367-0987                     333 Kennedy Street
www.marysvillemarine.com                            Oakland, CA 94606
                                                    (510) 533-9290 ˇ (800) 548-8658
MARYSVILLE MARINE DISTRIBUTORS WEST                 www.sea-power.com
405 South Thompson Road
Sun Prairie, WI 53590                               W ashington, I daho, N.W . United States and
(608) 825-3878 ˇ (800) 992-3878                     W estern Canada
                                                    MARINE POWER NORTHWEST
Tennessee, Kentuck y, M issouri, Kansas             1140 36th Street North
MARYSVILLE MARINE DIST. SOUTH                       Lewiston, ID 83501
855 Springfield Highway, Suite 104                  (208) 746-8621 ˇ (208) 746-8623
Goodlettsville, TN 37072
(615) 851-9456                                      Oregon, W estern California
                                                    MARINE POWER OREGON
Tex as                                              6445 Crater Lake Highway
PALMER POWER CORPORATION                            Central Point, OR 97502
6451 Rupley Circle                                  (541) 826-8488
Houston, TX 77087
(713) 644-6410 ˇ (800) 364-4637
www.palmerpower.com

DONOVAN MARINE
3130 Pawnee Street
Houston, TX 77054
(713) 734-4171 ˇ (800) 669-8392

Southern California, Arizona, Nevada, Haw aii
MARINE POWER WEST COAST
6310 Industrial Avenue
Riverside, CA 92504
(909) 343-0072




6
    9. ENGINE SPECIFICATIONS                                                                                       3.0L / 181 CID

                                                                                             C AR BU R ET ED


    ENGINE TYPE                                                                                INLINE 4

    CRANKSHAFT HORSEPOWER * (HP/KW)                                                            140 / 104

    DISPLACEMENT (LITER/CID)                                                                3.0L / 181 CID

    BORE & STROKE (INCHES)                                                                    4.00 x 3.60

    COMPRESSION RATIO                                                                           9.25:1

    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 (0.9MM)

    TIMING @ IDLE RPM                                                                          1/ ATDC

    TOTAL MAX TIMING ADVANCE @ 4000 RPM                                                       23/ TOTAL

    FIRING ORDER                                                                              1-3-4-2

    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 U.S. QUARTS

    CRANKCASE OIL (ADD 2/3 QT OIL FOR
                                                                               APPROXIMATELY 4 U.S. QUARTS
    EACH OIL FILTER USED ON ENGINE)

    T R ANSM IISSIONS: (See Transm ission Specifications 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.




                                                                                                                                           7
    9. ENGINE SPECIFICATIONS                                                                                      4.3L / 262 CID

                                                                     C AR BU R ET ED                              M PI


    ENGINE TYPE                                                                                 V-6

    CRANKSHAFT HORSEPOWER * (HP/KW)                                   225 / 167                               230 / 171

    DISPLACEMENT (LITER/CID)                                                              4.3L / 262 CID

    BORE & STROKE (INCHES)                                                                  4.00 x 3.48

    COMPRESSION RATIO                                                                          9.4:1

    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
                                                                                                     4.3 VORTEC - AC 41-932
                                                            4.3L VORTEC - MR43LTS

    SPARK PLUG GAP                                                                       .035 IN (0.9MM)

    TIMING @ IDLE RPM                                                      2/                              Set At Factory

    TOTAL MAX TIMING ADVANCE @ 4000                                       26/
    RPM

    FIRING ORDER                                                                        1-6-5-4-3-2

    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 U.S. QUARTS

    CRANKCASE OIL (ADD 2/3 QT OIL FOR
                                                                             APPROXIMATELY 4.5 U.S. QUARTS
    EACH OIL FILTER USED ON ENGINE)

    TRANSMISSIONS: (See Transmission Specifications 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.




8
  9. ENGINE SPECIFICATIONS                                                                                                            5.7L / 350 CID

                                                                                  C AR BU R ET ED                                       M PI


  ENGINE TYPE                                                                                                   V-8

  CRANKSHAFT HORSEPOWER * (HP/KW)                                                   315 / 235                                    325-335 / 242

  DISPLACEMENT (LITER/CID)                                                                               5.7L / 350 CID

  BORE & STROKE (INCHES)                                                                                    4.00 x 3.48

  COMPRESSION RATIO                                                                                             9.4:1

  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                                                         PRE-VORTEC - MR43T
                                                                                                                        5.7 VORTEC - AC 41-932
                                                                           VORTEC - MR43LTS

  SPARK PLUG GAP                                                                     .035 in.                               .060 in. (Platinium)

  TIMING @ IDLE RPM                                                                      8/                                             10/

  TOTAL MAX TIMING ADVANCE @ 4000                                                       26/
  RPM

  FIRING ORDER                                                         LH 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2            ˇ    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 U.S. QUARTS

  CRANKCASE OIL                                                             ALUM. PAN: APPROXIMATELY 7 U.S. QUARTS
                                                                          SHEET METAL PAN: APPROXIMATELY 5 U.S. QUARTS
                                                                             JETPAC PAN W/SINGLE FILTER: 8 U.S. QUARTS
                                                                             JETPAC PAN W/DUAL FILTERS: 9 U.S. QUARTS

  TRANSMISSIONS: (See Transmission Specifications 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
    9. ENGINE SPECIFICATIONS                                                                                      6.0L / 364 CID

                                                                                                M PI


    ENGINE TYPE                                                                                 V-8

    CRANKSHAFT HORSEPOWER * (HP/KW)                                                   375 HP @ 5200 RPM

    DISPLACEMENT (LITER/CID)                                                             6.OL / 364 CID

    BORE & STROKE (INCHES)                                                               4.00 X 3.62 IN.

    COMPRESSION RATIO                                                                          9.4:1

    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" (1.5MM)

    TIMING @ IDLE RPM                                                            COMPUTER CONTROLLED

    TOTAL MAX TIMING ADVANCE @ 4000                                              COMPUTER CONTROLLED
    RPM

    FIRING ORDER                                                                    1-8-7-2-6-5-4-3

    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 U.S. QUARTS

    CRANKCASE OIL                                                        APPROX. 6.5 QTS. PLUS FILTER(S)
                                                                    JETPAC PAN W/SINGLE FILTER: 7 U.S. QUARTS

    TRANSMISSIONS: (See Transmission Specifications 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




10
    9. ENGINE SPECIFICATIONS                                                                                             7.4L / 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                                                                                V-8

    CRANKSHAFT HORSEPOWER * (HP/KW)                                       330 / 246                                      380 / 282

    DISPLACEMENT (LITER/CID)                                                                 7.4L / 454 CID

    BORE & STROKE (INCHES)                                                                         4.25 x 4.00

    COMPRESSION RATIO                                                        8.0:1                                          8.6:1

    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 (0.9MM)

    TIMING @ IDLE RPM                                                         12/                                            12/

    TOTAL MAX TIMING ADVANCE @ 4000                                           32/                                            32/
    RPM

    FIRING ORDER                                            LH 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2            ˇ   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 U.S. QUARTS

    CRANKCASE OIL (ADD 2/3 QT OIL FOR                            ALUM. PAN: APPROXIMATELY 10 U.S. QUARTS
    EACH OIL FILTER USED ON ENGINE)                            SHEET METAL PAN: APPROXIMATELY 8 U.S. QUARTS

    TRANSMISSIONS: (See Transmission Specifications 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 C-3 SPECIFICAT IO NS.
**** T BI HP RAT ING SAME AS MPI




                                                                                                                                                 11
    9. ENGINE SPECIFICATIONS                                                                                      8.1L / 495 CID

                                                                  ST AN D AR D VOR T EC          H I-PER F H P2        H I-PER F H P 3

    E N G IN E T Y P E                                                                         V-8

    CRANKSHAFT HORSEPOWER * (HP/KW)                                   385 / 287                  450 / 335             550 / 410

    DISPLACEMENT (LITER/CID)                                                              8.1L / 496 CID

    BORE & STROKE (INCHES)                                        BORE: 4.25" (107.95MM)            STROKE: 4.37" (111MM)

    COMPRESSION RATIO                                                                          9.1:1

    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 #810E-210)

    SPARK PLUG GAP                                                                        .059 IN (1.5MM)

    TIMING @ IDLE RPM                                                            COMPUTER CONTROLLED

    TOTAL MAX TIMING ADVANCE @ 4000                                              COMPUTER CONTROLLED
    RPM

    FIRING ORDER                                                                    1-8-7-2-6-5-4-3

    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 U.S. 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 U.S. QUAR T S
    FILTER U SED O N ENG INE)                                       SH EET M ETA L PA N: APPR OXIM AT ELY 8 U.S. QUAR T S
                                                                        JETPA C PA N W /SING LE FILTER : 7 U.S. QUAR T S
                                                                         JE TPA C PA N W /D U A L FILTER : 8 U.S. QUAR T S

    T R ANSM ISSIONS: (See Transm ission Specifications 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




12
    9. ENGINE SPECIFICATIONS                                                                                        8.2L / 502 CID

                                                                     C AR BU R ET ED                               M PI

    E N G IN E T Y P E                                                                            V-8

    CRANKSHAFT HORSEPOWER * (HP/KW)                                                            450 / 335

    DISPLACEMENT (LITER/CID)                                                                8.2L / 502 CID

    BORE & STROKE (INCHES)                                                                    4.47 x 4.00

    COMPRESSION RATIO                                                                            8.75:1

    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 (0.9MM)

    TIMING @ IDLE RPM                                                     12/                                      12/

    TOTAL MAX TIMING ADVANCE @ 3500                                       32/                           Computer Controlled
    RPM

    FIRING ORDER                                                                       1-8-4-3 -6-5-7-2

    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 U.S. QUARTS

    CRANKCASE OIL (ADD 1 QT OIL FOR                                 ALUM. PAN: APPROXIMATELY 10 U.S. QUARTS
    EACH OIL FILTER USED ON ENGINE)                               SHEET METAL PAN: APPROXIMATELY 8 U.S. QUARTS
                                                                     JETPAC PAN W/SINGLE FILTER: 7 U.S. QUARTS
                                                                      JETPAC PAN W/DUAL FILTER: 8 U.S. QUARTS

    TRANSMISSIONS: (See Transmission Specifications 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




                                                                                                                                            13
    9. ENGINE SPECIFICATIONS - "X" PERFORMANCE MOTORS                                                                                            500X / 530X


                                                                                      500X C arbureted                                          530X PFI

    EN G IN E T Y PE                                                                                                    V-8

    C R AN K SH AF T H OR SEPO W ER * (H P/K W )                                           500 / 373                                            530 / 395

    D ISPL AC EM EN T                                                                                                   8.2L

    BOR E & STR OK E (IN C H ES)                                                                                    4.47 X 4.00

    C O M PR ESSIO N R AT IO                                                                  9.6:1                                               9.6:1

    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                                                                                       1-8-4-3-6-5-7-2

    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 71-72C SER IES 1:1                                                                      2 U .S. Q U AR T S (1.9L )

    BO R G W AR N E R 71-72C SER IES 1.5 - 2.9:1                                                              3 U .S. Q U AR T S (2.8L )

    BO R G W AR N E R 5000 SER IES 1:1 - 2.8:1                                                                2 U .S. Q U AR T S (1.9L )

    BO R G W AR N E R V-D R IVES (AL L R AT IO S)                                                             4 U .S. Q U AR T S (3.8L )

    Z F 63A SER IES                                                                                          3.2 U .S. Q U AR T S (3.0L )

    Z F 63V SER IES                                                                                          4.2 U .S. Q U AR T S (4.0L )

    Z F 45D SER IES                                                                                          2.1 U .S. Q U AR T S (2.0L )

    Z F 45A SER IES                                                                                          3.2 U .S. Q U AR T S (3.0L )
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.




14
 10. A WORD TO THE " DO-IT-YOURSELFER"

The past twenty years has seen a revolution in the way both automotive and marine engines are built. The most
revolutionary 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 carburetor
injected 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 screwdriver.

Today it is much different. EFI engines are operated by a computer and sophisticated engine calibrations.
These 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 replaced.

Marine engine technicians receive specialized training in the diagnosing and correcting of EFI equipped
engines. 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

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 rpm's 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 and
distributor caps can make all the difference in the world in performance versus being towed back in.


 GASOLINE

Gasoline 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 plugs,
pistons, and valves. Any engine stored for thirty (30) days or longer needs a fuel stablizer. We recommend that
STA-BILŽ be added to the fuel per the manufacturer's directions. This will prevent the formation of harmful
varnish 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 responsibility 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 is
recommended that a competent marine service facility be contacted to perform the winterization or storage.




                                                                                                                  15
        THIS PAGE
       LEFT BLANK
     INTENTIONALLY




16
                                            SECTION TWO



                                GENERAL INFORMATION

11. General Informatio   .n
                          .......................................................................... 18-24
       Engine Compartment            ................................................................   18
       Engine Mountin.      g.......................................................................    18
       Engine Be   .d
                    ................................................................................    18
       Sea Water Pipin.g      ......................................................................    18
       Fuel Line .s
                  ..................................................................................    19
       Electrical Connection         .s
                                      ...............................................................   19
       Exhaust Pipin.    g..........................................................................    19
       Hydro-Loc   .k
                    ................................................................................    20
       Water Inversio.n    .........................................................................    20
       Detonation &/or Pre-Ignitio.n           ......................................................   20
       Pre-Start Checklis      .t
                                ....................................................................    21
       Gasoline Recommendatio.n               .......................................................   21
       Starting Engine-Carbureted             .......................................................   21
       Starting Engine-EF       ..I..................................................................   22
       Proper Engine Break-In           .............................................................   22
       10 Hour Servic     .e
                           .........................................................................    23
       Engine Rotation Information.....................................................                 24
       Propeller Informatio.n       .................................................................   24




                                                                                                             17
 11. GENERAL INFORMATION


 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
 installations. If engine is equipped with a closed
 cooling system, it is im perative to fill the system
 with a 50/50 mix of ethylene glycol base
 antifreeze and clean fresh water. Failure to use a
 50/50 mixture of antifreeze and water can result
 in engine damage. (See Eng ine Specification
 Section)


 ENGI NE COM PARTM ENT                                                          ENGINE BED

The engine compartment should be well-planed giving
consideration to accessibility and ventilation. Engines
must have air as well as fuel to operate efficiently.
The 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 result.
Engine 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 through-hull fitting and sea cock should be
                                                             placed as close to the engine as possible and be one
encountered.
                                                             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.
                                                             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 non-collapsing type. It is highly recommended
design and
                                                             that a sea strainer of adequate size be installed
heavily
constructed                                                  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                                             overheating.
between the oil pan or other components located in
that area and the hull.



18
 11. GENERAL INFORMATION - Continued

                                                           Marine Power requires installation of external
 FUEL LI NES                                               and internal flappers to prevent hydro-lock.
                                                           Hydro-lock 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, i.e.
A 3/8" minimum (inner-dimension) "Type A1" USCG            tunnel drive or negative engine installation angles,
Approved tubing is recommended for the fuel line           such as V-Drives. Consult your dealer.
from the tank to the engine for all 181/3.0L, 262,4.3L
and 350/5.7L engines. All 6.0L and larger engines
must be ˝" minimum inner dimension. It should be
adequately secured and provided with a flexible
section near the engine to reduce vibration to the line.
Fittings for the tubing should conform to current Coast
Guard or American Boating & Yacht Council
standards. 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 hull
requirements and should be anchored securely and
vented in such a manner to conform to Coast Guard
regulations. The fuel tank filling arrangements should
conform 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 U.S.
Coast Guard or American Boating & Yacht Council
standards.


 EXHAUST PI PI NG

 WARNING! MARINE POWER does not
 warranty items damaged due to Hydro-Lock.

Exhaust hose(s) must be installed to prevent water
from returning to engine. Exhaust hose(s) must have
a definite slope to the transom of not less than ˝" per
foot of length. If pipe is used in the exhaust line
installation, it must be separately supported so the
weight of the pipe is not carried by the exhaust
manifold outlets.




                                                                                                             19
 11. GENERAL INFORMATION - Continued

                                                          To minimize this problem Marine Power requires the
 HY DR O-LOCK                                             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 slow-downs 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 four-cycle 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          spark-ignited 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 low-octane 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 quality/octaine
                                                          # Improper initial ignition timing setting
                                                          # Improper propeller selection
 W ATER I NVERSI ON                                       # Engine overload, such as operating twin-engine
                                                              boat with only one engine
Water inversion is water that is pulled back into the     # Improper cooling operation resulting in engine
exhaust and usually ends up in the piston cylinder.           overheating
Most of the time this happens under the following         # Fuel starvation or vapor lock resulting from
conditions:                                                   poor fuel quality / lean out
    ˇ Shutting off engine at high RPM's                   # Malfunctioning carburetor causing lean mixture
    ˇ Water comes up the exhaust after a quick            # Operating engine that is out of proper tune,
        slowdown                                              dead cylinder, defective distributor cap
    ˇ Long periods of idling                              # Excessive exhaust backpressure caused by
    ˇ Exhaust drop not sufficient                             restricted exhaust mufflers or outlets

Usually 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 is
catastrophic due to the rusting.




20
 11. GENERAL INFORMATION - Continued

                                                           fuel lines are possible. If this type of gasoline is
 P R E-START 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 (12-14V) is necessary to
                                                           crank a cold engine. At lower temperatures a richer
IMPORTANT! MARINE POWER requires that your                 fuel mixture is desired at startup. For carbureted
servicing dealer perform a sea trial for proper            engines, you may have to pump the throttle control
completion of your warranty/sea trial form. Failure to     more than usual while cranking the engine to start.
properly registered your engine will result in delay
receiving 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 50/50 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" instructions.)
                                                                compartment.
4.   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 1/4 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 temperature:

 GASOLI NE R ECOM M ENDATI ON                              Raw Water Cooling:       Operating temperature
                                                           should be 140 - 165 degrees.
Marine Power recommends the use of unleaded
                                                           Closed Cooling: Operating temperature should
gasoline of at least 87 octane to insure adequate
engine performance.                                        range 160 - 190 degrees.

ALCOHOL ADDED GASOLINE:

Use of ethanol or methanol type gasolines are not
recommended for use in your Marine Power engine.
Adverse effects such as, but not limited to, corrosion,
excessive wear to internal parts, or damage to flexible

                                                                                                              21
 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 twenty-five (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 temperatures.
                                                            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.
 break-in period) near or at maximum rpms in
 rough water conditions wherein the craft may              2.   VOLTMETER: Normal reading is 13.0 -14.5
 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 RECOMMENDATIONS                                in gear. Note: For Jetpac applications, normal
 WILL VOID THE TERMS OF WARRANTY .                              reading is 800-1000 RPM.

To insure maximum life of your MARINE POWER                6.   THROTTLE AND SHIFT CONTROLS: Check
engine, the following engine break-in schedule is               that movement is not constrictive. Verify that
recommended:                                                    linkage is adjusted so that engine may reach
                                                                Wide Open Throttle (WOT).
First hour - Perform sea trial.
                                                           7.   EXHAUST, OIL, WATER AND FUEL
IMPORTANT! During the break-in period, pay close                SYSTEM: Inspect for leaks. Be sure to check
attention to the following steps.                               riser bolt tightness after 10 hours and every 50
                                                                hours of operation. Refer to Maintenance
1.   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 break-in         It is very important to re-tighten 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 non-warrantable
                                                           engine damage.
IMPORTANT! 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.




                                                                                                              23
 11. GENERAL INFORMATION

 ENGINE ROTATION                                          PROPELLER W ARNI NG

Directional references used in this section are given
as if standing behind the boat, looking forward:          WARNING! MARINE POWER does not warranty
      ˇ front of boat is bow                              items damaged due to detonation. The propeller
                                                          selected should allow the engine to operate at or
      ˇ rear of boat is stern
                                                          near the recommended wide open throttle RPM
      ˇ right side is starboard
                                                          range with a normal load. Wide Open Throttle
      ˇ left side is port
                                                          RPM range is listed in Engine Specification
                                                          Section.
The raw water (or seawater) pump is located at the
front of the engine on the crankshaft pulley. Engine
rotation 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 engine's performance and life.

Left Hand Engines: CCW or Normal Rotation
Right 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 differently.

                                                         Testing for a correct propeller is accomplished by
                                                         operating the boat (with an average load) at Wide
                                                         Open Throttle (WOT) rpm's 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 and/or pitch
                                                         of the propeller is required. Newly installed engines
                                                         operating 100 - 300 RPM below wide open throttle is
                                                         usually a propeller problem.




24
                                            SECTION THREE



                                  ROUTINE MAINTENANCE

   12. Routine Maintenanc.        e................................................................... 26-36
          How To Use This Section                .......................................................  26
          Please Be Carefu         ..l.................................................................   26
          Troubleshootin      .g......................................................................    26
          Crankcase Oil Chang.              e
                                            ...........................................................   26
          Ambient Oil Temperature              ........................................................   27
          Oil Filte.
                   r.s
                     ................................................................................     27
          Starter (Top Mount Only             ..).......................................................  28
          Flame Arresto     ..r
                              .......................................................................     28
          Carburetor Fuel Filte          .r
                                          .............................................................   28
          Changing Carburetor Fuel Filter-Holley                      ..................................  28
          Water Separating Fuel Filte               ..r
                                                      ..................................................  29
          Changing Fuel/Water Filte                .r
                                                    ....................................................  29
          G-Force Fuel System............................................................                 29
          Battery Cables     ........................................................................     29
          Multiple Engine Battery Precautions-EF.I...............................                         30
          Alternation Belt Tensio.            n
                                              .........................................................   30
          Checking Belt Tension            ............................................................   30
          Delco EST Ignition - Using Timing Tool: Carbureted Engine                                   ..  31
          Engine Tune-Up.         s...................................................................    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.                     r.............................................  35
14.    Scheduled Maintenance By Qualified Technician                            ........................  36




                                                                                                               25
 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 rapidly
maintenance of Marine Power engines. Whether the               corrode and engine failure could result. Warranty
reader 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                   used.
procedure. Make sure you are familiar with the tools
suggested and the methods recommended. Safety is
                                                                TROUB LESHOOTI NG
our first concern. If repair required is beyond your
expertise, please contact your dealer or other qualified
technician.                                                    If a problem is detected, contact your Marine Power
                                                               selling/installing dealer first. He is trained to diagnosis
This 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 Troubleshooting 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 maintenance
Electrical, ignition and fuel system components on             schedule has been prepared to help the operator
Marine Power engines comply with U.S. Coast Guard              care for his or her new engine.
(USCG) 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 trouble-free 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. Always
disconnect 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 Control
exhaust 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 discharge
Care 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 re-use the same bolt,           Violators are subject to a penalty of $5000.
do not improvise.




26
 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 thermo-expansion 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           1-5 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 oil
throughout. Inspect entire engine for leakage. Shut        NOTE: Lay a towel or catch basin under the filter(s)
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 removed,
Marine Power does not recommend the use of                      clean mounting base. Be sure old gasket is
multi-viscosity, non-detergent type oils. Oils that             removed from mounting base.
contain solid additives or low quality oils (other
than 20W-40 or 20W-50) are also not                        2.   Apply thin film of oil (do not use grease) to filter
recommended.                                                    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.




                                                                                                                   27
 12. ROUTINE MAINTENANCE - Continued


 STAR TER (TOP M OUN T ON LY )

Starters are notorious for problems due to moisture
and corrosion.

However, Marine Power uses a top-mounted rear
entry starter on most Sportpac and Jetpac models,
that reduces starter problems and is more accessible.

Spray 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 regularly.

1.   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 assemble.




                                                          HOLLEY




28
 12. ROUTINE MAINTENANCE - Continued


 W ATER SEP AR ATI NG FUEL FI LTER                          B ATTERY CAB LES

IMPORTANT! 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 ventilated
properly.
                                                            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 counter-clockwise. 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 3/4 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 OVERTIGHTEN.

4.   Start engine and inspect for leaks.


 CHANGI NG FUEL/ W ATER FI LTER




 G-FOR 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 o-ring (included with filter).
7.   Re-install cannister bowl on unit-snug tight only.
8.   Two 10-second key ups should prime system.

                                                                                                              29
 12. ROUTINE MAINTENANCE
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
                                                           spring-loaded tensioner.       Normally, no
batteries for two separate engines are connected, one
alternator will supply all the charging current for both   maintenance is required.
batteries. In normal instances, the other engine's
alternator will not be required to supply any charging
                                                            CHECK I NG B ELT TENSI ON
current.

The Electronic Control Module (ECM) requires a
steady, stable voltage source. In multiple engine
operation, an electrical onboard device may cause a
sudden drain of voltage at the engine's battery. The
voltage may go below the ECM's minimum required
voltage of nine (9) volts and the idle alternator on the
other engine may now start charging. This could
cause a voltage "spike" in the engine's electrical
system. 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 multi-EFI
power 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 own
individual battery. DO NOT run engines with the
battery switches in "BOTH" or "ALL" positions.
This will allow the other engine's 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 the
circulating pump pulley. The belt should depress
one-quarter inch. If belt depresses more than
one-half inch, loosen alternator mounting screw




30
 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 distributor.

For EFI Engines - Refer to EFI Section                    10. Check total timing at 4000 RPM. (See Engine
                                                              Specifications Section.)
The timing tool is used in setting the initial engine
timing on MARINE POWER carbureted engines. This           11. Disconnect and remove the timing light.
connector by-passes the electronic spark timing of
the engine and allows the initial timing to be adjusted
by rotating the distributor. Use the following
procedure (become familiar with entire procedure
before beginning):

The ignition timing marks are located on the engine's
front cover. A saw slot on the balancer indicates
engine at (TDC) Top Dead Center. Adjust ignition
timing 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 ALTERNATOR.)

2.   Start engine and allow to warm to operating
     temperature. Bring engine to idle (650-800
     RPM).

3.   WHILE ENGINE IS RUNNING, install the timing
     tool supplied with your engine into the terminal
     connector on the distributor.

4.   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
     SPECIFICATIONS"           SECTION OF THIS
     MANUAL FOR CORRECT TOTAL AND
     INITIAL TIMING FOR YOUR ENGINE.




                                                                                                          31
 12. ROUTINE MAINTENANCE - Continued

                                                          The cooling system does require certain preventative
 ENGI NE TUNE-UP S                                        maintenance to keep it in optimum operating
                                                          conditions.
Refer to Maintenance Chart for tune-up 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.   Re-install 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% water/50% antifreeze) to
6.   Check spark plug wires for deterioration and/or      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 SYSTEM
lake/river/sea 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 personal
engine.)                                                   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 year-round with the proper mixture
extended life to your new Marine Power engine. Your        of 50% antifreeze/50% water to assure protection
engine will operate at a different temperature range       of system during the lowest exposed
from a raw water cooled engine. Please refer to the        temperatures.
appropriate engine specification page for proper
cooling ranges.




32
 12. ROUTINE MAINTENANCE - Continued

FILLING 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 50/50                   and engine will be damaged.
    antifreeze/water 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:
    #      3.0L/181 Side Mount Full System: Heat           !   V6-V8 blocks must be drained on both sides. Drain
           exchanger cap is sufficient.                        plug locations are as follows:
    #      4.3L/5.7L Front Mount Full System: Heat             # 3.0L/181: Single plug on port side of lower
           exchanger cap is sufficient.                            block.
    #      4.3L/5.7L Rear Mount Full System:                   # 4.3L/5.0L/5.7L/7.4L/8.2L Carbureted: Plug on
           Disconnect hose from top of circulating water           lower center portion of block on each side.
           pump.                                               # 4.3L/5.7L EFI: Knock sensor is located in port
    #       6.0L Side Mount Full System: Air bleed on              block drain. Sensor must be removed for
           starboard exhaust manifold.                             draining and retorqued to 22 ft.lb. When re-
    #      8.1L Side Mount Full System: Open pet                   installed.
           cock on water tube crossover and remove             # 6.0L: Plug on starboard side is vertically
           1/8" 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
    #      7.4L/8.2L Front Mount Full System: Heat                 to lower block surface. Use 17mm Allen
           exchanger cap is sufficient.                            wrench to remove.
    #      7.4L/8.2L Rear Mount Full System:                   # 8.1L: 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       !   Re-install 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. 6.0L         sealant and re-install into proper locations.
    and 8.1L 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
                                                              STA-BILŽ be added to the fuel per the manu-
                                                              facturer's 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 Procedures.)

                                                           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.




                                                                                                                 33
 12. ROUTINE MAINTENANCE - Continued

CLOSED 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:
   ˇ 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.
       5.0/5.7V EL models.
   ˇ Engine block does not need draining                3. Inspect bilge area and around engine for nesting
   ˇ 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 anti-corrosion battery terminal
   section.                                                spray be use to coat terminal connections.

                                                        5. After engine is started, monitor gauges to insure
 FOGGI NG P R OCEDUR ES                                    engine is operating in normal operating
                                                           temperatures.
This 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
   carburetor.


  CAUTION
 Do not pour an excessive amount of oil into the
 carburetor at one time. This can cause engine to
 stall and/or create a hydraulic lock condition in a
 cylinder resulting in engine damage.

4. Turn ignition switch off.

5. Clean flame arrestor and re-install 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 season
start-up time should be minimal. Please do the
following before attempting to start your engine.




34
 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 START-UP EACH DAY AND ONCE EVERY EIGHT (8) HOURS OF OPERATION




                                                                                                   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 FUEL/WATER 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




36
                                         SECTION FOUR



                                      ENGINE DIAGRAMS
15.   Coolant Flow Diagram: Raw Water Cooling 181                     ................................   38
16.   Coolant Flow Diagram: Raw Water Cooling V6/V8                       ............................   39
17.   Coolant Flow Diagram: Closed Cooling 181                 .......................................   40
18.   Coolant Flow Diagram: Closed Cooling Front Mount V6/V8                           ...............   41
19.   Coolant Flow Diagram: Closed Cooling Rear Mount V6/V8...............                               42
20.   Primary Engine Wiring Harness: Carbureted/Electric Fuel Pump......                                 43
21.   Shift Assist Wiring Diagram: Carbureted Merc & Early OMC.............                              44
22.   TBI Shift Interrupt Wiring Diagram        ......................................................   44
23.   Initial Timing Jumper Wiring Diagram           .................................................   45
24.   Shift Interrupt - OM.C
                           ...........................................................................   45
25.   EFI Primary Engine Wiring Harness            ...................................................   46
26.   EFI Secondary Engine Wiring Harness               ..............................................   47
27.   Engine Instrument Panel Wirin.g        .........................................................   48




                                                                                                              37
15. COOLANT FLOW DIAGRAM - RAW WATER COOLING SYSTEM   181




38
18. COOLANT FLOW DIAGRAM - CLOSED COOLING - FRONT MOUNT   181




                                                           41
26. EFI SECONDARY WIRING HARNESS




                                   47
                                   SECTION FIVE


                      TROUBLESHOOTING GUIDE
28.   Troubleshooting Guide...............................................................50-54
         Engine Will Not Turn Over..................................................         50
         Engine Cranks But Will Not Start          ........................................  50
         Engine Starts and Stops - Carbureted             .................................  50
         Engine Starts and Stops - EF.I............................................          50
         Engine Runs Poorly At Idle and Acceleration.....................                    51
         Engine Runs Poorly At High RPM             .......................................  51
         High Speed Miss  .................................................................  51
         Fuel System - Ric. h..............................................................  52
         Fuel System - Lean   .............................................................  52
         Poor Fuel Econom.y   .............................................................  52
         Oil Pressure - Low................................................................  52
         Oil Pressure - Hig.h..............................................................  53
         Excessive Oil Consumption................................................           53
         Engine Overheating   .............................................................  53
         Water In Engine Cylinder or Bas.          e.......................................  54
29.   Excessive Oil Consumption Troubleshooting Chart                    ..................  55
30.   Warranty Registration Transfer Form          ........................................  56



                             SERVICING DEALERS
      Servicing Dealers Information...................................................     57




                                                                                                  49
 28. TROUBLESHOOTING GUIDE

The following troubleshooting 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
 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 cylinder


Engine 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 RPM's         Check Battery Voltage
 Check Distributor Cap & Rotor       Replace
 Fouled Plugs                        Replace
 Engine Timing                       Re-time
 Correct Firing Order                Check / Correct
 Low Compression
 Bad / Old Fuel
 Fouled Carburetor

 ENSURE A TUNE UP IS DONE EVERY 100 HOURS OR EVERY SEASON


Engine 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
 Compression


Engine 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 Supply




50
28. TROUBLESHOOTING GUIDE

Engine Runs Poorly At Idle and Acceleration
POSSIBLE CAUSE                        REMEDY

Incorrect Firing Order                Check / Adjust/ Replace
Incorrect Ignition Timing
Choke Adjustment
Faulty Spark Plug
Contaminated Carburetor               Check for sticking or burnt valve or broken valve spring.
Internal Cylinder Head Problem
Engine Surge, Stall, Lack Power       Carburetor float adjustment, Power Piston, Leaking Gaskets


Engine Runs Poorly At High RPM
POSSIBLE CAUSE                        REMEDY

Low Grade or Old Fuel                 Check / Clean / Replace
Ignition Timing
In Need of a Tune-UP
Ignition Coil
Engine Overheating
Restricted Exhaust
Overfilled Crankcase
Plugged Fuel Tank Vent
Restricted Anti-Siphon Valve
Restricted Exhaust
Low Compression

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
Insufficient fuel supply
Spark plug or wires
Faulty distributor Module
Loose ignition connection
Ignition coil
Ignition timing. Total advance
incorrect
Faulty tachometer
Faulty fuel pump
Loose electrical connection at fuel
pump
Detonation




                                                                                                   51
28. TROUBLESHOOTING GUIDE

Fuel System - Rich
POSSIBLE CAUSE                       REMEDY

Dirty / Clogged Flame Arrester       Check / Clean / Replace
Carburetor Float Adjustment
Carburetor Gasket Leaking
Return Line Not Directed Back To
Tank


Fuel System - Lean
POSSIBLE CAUSE                       REMEDY

Empty Fuel Tank
Vapor Lock
Automatic choke                      Stuck open, adjust


Poor Fuel Economy
POSSIBLE CAUSE                       REMEDY

Boat Hull Dirty                      Clean / Check / Adjust
Incorrect Prop Size or Damage
Clogged Flame Arrester
Tune -up
Low Engine Compression
Engine Running Too Hot or Cold
Incorrect Fuel Grade
Boat Overload
Weight Distribution
Carburetor Settings
Incorrect 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 levels
Excessive oil in crankcase           Remove excess oil. Refer to owner manual for correct oil levels
Erroneous oil gauge readings         Contact dealer to perform a mechanical oil pressure check
Incorrect Dipstick
Oil line position and routing
Incorrect oil viscosity or diluted
Oil Pump malfunctioning
Oil leak
Excessive Bearing Clearance          Rod, Cam or Main Bearings

Engine oil pressure as low as of 5 pounds at idle is acceptable. At 2000 rpm 30 pounds is acceptable




52
 28. TROUBLESHOOTING 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 dealer


Excessive Oil Consumption
 POSSIBLE CAUSE                         REMEDY

 External Leak                          Clean / Check / Adjust
 Excessive oil in crankcase
 Oil / Fuel dilution
 Extended excessive RPM's
 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 rpm's


Engine Overheating
 VERIFY IF ENGINE IS ACTUALLY OVERHEATING.

 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




                                                                                                            53
28. TROUBLESHOOTING GUIDE

Engine Overheating (Continued)
VERIFY IF ENGINE IS ACTUALLY OVERHEATING.

POSSIBLE CAUSE                          REMEDY

Water hoses reversed                    Mix to a 50 /50 ratio
Exhaust riser obstruction
Transmission cooler blocked
Air leak in hose                        Riser should be changed every three to four years.
Slipping circulating pump belt
Head gasket failure                     See dealer


Water In Engine Cylinder or Base
POSSIBLE CAUSE                          REMEDY

Operator error                          See Boater's Beware. REMOVE water from engine immediately
Exhaust restricted or blocked           Repair or Replace. REMOVE water from engine immediately
Engine and exhaust too low in
boat                                    Redesign 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 head gasket 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 two 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.




54
29. EXCESSIVE OIL CONSUMPTION TROUBLESHOOTING CHART



                 CAUSE                                    INFORMATION

Normal Oil Consumption               One quart of oil consumed within 5-15 hours of wide-open
                                     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 leak(s).
Oil Too Thin                         Oil diluted or wrong viscosity.
Cylinder Head Drain Holes Plugged    Oil will flood valve guides.
Defective Valve Seals
Leaking Intake Manifold Gasket
Worn Valve Guides or Valve Stems
Defective Piston Rings               Worn, stuck, glazed, scuffed, improperly installed
                                     ring grooves worn, improper break-in; Wrong end
                                     gap.
Defective Cylinders                  Scored, tapered, glazed, out of round; Excessive
                                     piston to cylinder clearance; cracked piston.
Excessive Bearing Clearance
Defective Oil Cooler (if equipped)   Crack in cooler tubes.




                                                                                             55
                                         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 NER'S PHONE NU M BER

 A /C                    PH ON E           -




PLEASE ENCLOSE CHECK OR MONEY ORDER IN THE AMOUNT OF $50.00 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

Your application will be processed and a new warranty card will be sent in approximately three (3)
weeks from receipt of this transfer application.




56
  SERVICING DEALERS




          SERVICING
           DEALERS



Note: If You Are Unable to Locate a
  Independent Servicing Dealer,
  Please Contact a Marine Power
   Distributor Closest to You for
        Further Assistance.




                                      57
             SERVICE AND MAINTENANCE RECORD

                                                           OPERATING
     DATE   SERVICE/MAINTENANCE PERFORMED   PERFORMED BY
                                                             HOURS




58


Ad by Google

Disclaimer:
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.