Marine Power 4.3 VORTEC MPI, Owner'S Manual

Page 1: ...E N G I N E O W N E R S M A N U A L VERSION 3 ...

Page 2: ...me Arrestor 28 G Force Fuel System 28 Battery Cables 29 Multiple Engine Battery Precautions EFI 29 Alternator Belt Tension 29 Sea Water Pump Impeller Replacement 29 Closed Cooling System 30 Filling Closed Cooling System 30 31 Section 11 Engine Diagnostics and Codes 32 34 Section 12 Trouble Shooting Engine Will Not Turn Over 35 Engine Cranks But Will Not Start 35 Engine Runs Poorly at High RPM 36 H...

Page 3: ...ith these warning instructions while performing service and maintenance procedures plus common sense The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Electrical ignition and fuel system components are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize the possibi...

Page 4: ...ease read the Limited Warranty 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 performed without prior authorization from the Marine Power Distributor in your area Contact your selling dealer directly for any required warranty repairs For more information you may also visi...

Page 5: ...r warrants that each Marine Power Inboard marine engine and factory installed accessories designed built and equipped with all applicable regulations adopted by the Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code and the U S Environmental Protection Agency pursuant its authority in Chapter 9 of Title 5 of the U S Code to be free fr...

Page 6: ...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 Throughout the appropriate warranty period in the table from the previous page Marine Power will maintain a supply of warranted parts sufficient to meet the expected demands for such parts 10 Any replacem...

Page 7: ...sing from installation application exhaust to engine fuel lines to the engine propping cooling to the engine or engine damage due to defective electrical hookups C Rust corrosion or effects of weather D Water ingestion through exhaust or intake system E Detonation or operation with fuels oils or lubricants which are not suitable for use with this product Detonation causes Poor fuel quality overloa...

Page 8: ...on engines heaters charcoal grills cooking ranges and any other open flame appliances There are many possible variables for the accumulation of carbon monox ide 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 condu...

Page 9: ...r stern drive I O applications Cooling water supply differs depending on the stern drive model mated to See Section 12 Installation Instructions Jetpac Engines configured for inboard jet drive applications Cooling water normally supplied by jet drive Routing of inlet out outlet cooling water lines will affect winteriza tion See Section 9 Winterization procedures Towpac Engines configured for water...

Page 10: ... ECM Controlled 60 PSI 4 7 PSI 30 60 PSI 10 PSI 143 F 165 F 12568387 AC 41 101 060 ECM Controlled ECM Controlled 1 8 4 3 6 5 7 2 95 amps 15W 40 Jets 6 Qts Other 5 Qts Antifreeze Water 10 Qts 6 2 LS3 V8 X X Light Weight 6 2L 374 CID 103 25 x 92 mm 10 7 1 Aluminum Aluminum 91 Octane 5600 ECM Controlled 60 PSI 4 7 PSI 30 60 PSI 10 PSI n a 170 190 F 12621258 AC 41 110 040 ECM Controlled ECM Controlled...

Page 11: ...onitorstheoilpressureandwater temperature The following sensors constantly provide information to the ECM Engine Coolant Temperature ECT Sensor Engine Oil Pressure Sensor Manifold Absolute Pressure MAP Sensor Knock Sensor Camshaft Positioning CMP Sensor Crankshaft Positioning CKP Sensor Intake Air Temperature IAT Sensor combined with the MAP sensor on the 5 7 Throttle Position TPS Sensor Pedal Pos...

Page 12: ...become intermittent but a trouble code will be logged for future diagnosis In any case the operator must obtain service by an authorized dealer to determine and repair the exact cause of the malfunction The engine ECM is programmed to control the engine alarm system This system is configured to turn on an instrument panel mounted indicator MIL or Check Engine light and optionally an audible buzzer...

Page 13: ...ould understand his instrumentation and note any abnormal operating conditions Analog Instrumentation Canbus Instrumentation IMPORTANT Enginesaredesignedtouse both buzzers and MIL lamps Buzzers are usetoalertoperatorsofsevereproblems such as Low oil pressure high engine temperature or low fuel pressure See Section 11 Engine Diagnostics and Codes for more information ...

Page 14: ...osure All relays and fuses are located in the Severe Service Vessel Electrical Center SSVEC This enclosure is capable of withstanding direct water spray Additional ly it contains a Goretex vent which allows humid vapors to escape without allowing water in ...

Page 15: ...13 www MarinePowerUSA com 6 SSVEC Fuse and Relay Enclosure ...

Page 16: ...14 www MarinePowerUSA com 6 SSVEC Fuse and Relay Enclosure ...

Page 17: ...15 www MarinePowerUSA com 6 SSVEC Fuse and Relay Enclosure ...

Page 18: ...ransom of your boat 2 Engine Shutdown Sudden engine shutdown while the boat is moving may force water into the exhaust system 3 Improper Installation Refer to Section 12 Exhaust Piping An exhaust system without flappers and the specified incline increases the likelihood of water entering the engine 4 Improper Hoisting Operators are sometimes tempt ed to reduce hoisting time for propeller changes b...

Page 19: ... year and that the engine oil filter be replaced every time the engine oil is changed Starting Engine EFI DO NOT operate engine without water being supplied to raw water pump as pump impeller and engine will be damaged Operate the bilge blower for five 5 minutes If not equipped with a bilge blower open engine hatch and leave open before starting the engine to remove any explosive vapors from the e...

Page 20: ...ne speed to 3500 RPM Avoid running the engine at a constant steady RPM for sustained periods of time i e vary the throttle engine speed frequently Check the engine oil level at the beginning of each boating day and after each 2 3 hours of engine operation Any time oil level is checked look for milky discoloration if found consult with your dealer After the first ten 10 hours of engine operation bu...

Page 21: ...installed 3 Remove engine oil and transmission cooler drain plugs 4 Remove hoses from sea water pump if applicable Remove circulating pump hose from lower inlet to circulating pump Remove all exhaust manifold drain plugs Drain engine completely 5 Any engine stored for thirty 30 days or longer needs a fuel stabilizer We recommend that Sta Bil be added to the fuel per the manufacturer s directions T...

Page 22: ...l cooler Remove drain plugs if equipped from exhaust risers Note the routing of your inlet cooling water hose to make sure there are no locations which may trap water If your engine is attached to a v drive transmission pay particular attention to the draining of the v drive cooler Remove end caps on heat exchanger Inspect for debris and trapped water Remove zinc anode and replace if necessary Spr...

Page 23: ...ust manifold do not require the removal of the manifold drain as it will drain once the heat exchanger end cap is removed Note the routing of your inlet cooling water hose to make sure there are no locations which may trap water If your engine is attached to a v drive transmission pay particular attention to the draining of the v drive cooler Remove end cap on heat exchanger Inspect for debris and...

Page 24: ...22 www MarinePowerUSA com Remove Blue Plug from Manifold Fitting Remove Drain Plugs from V drive 9 Winterization Remove Hoses from Sea Water Pump ...

Page 25: ...board Jet Engines Test antifreeze water concentration to assure adequate protection for your location These engines are designed to be self draining however it is recommended that the heat exchang er ends be inspected for debris and trapped water frequently ...

Page 26: ...in Tank If Equipped with Closed Cooling 3 3 Inspect and Clean Sea Strainer If Equipped 3 3 Inspect Entire Power Package for Leaks Water Fuel Oil Exhaust etc 3 3 3 Inspect Belts for Tension and Wear 3 3 3 Inspect Battery Terminals and Fluid Levels 3 3 3 Check Battery Connection to Engine 3 3 3 Touch Up Exterior Surface with Marine Power Paint 3 3 3 Inspect Zinc Anodes in Heat Exchanger for Deterior...

Page 27: ...ing Engine Parts 3 3 Check Wire Harness Plugs for Corrosion and Connections 3 3 Inspect Distributor for Cracks or Deterioration 3 3 Check Condition of Spark Plugs Replace if Necessary 3 3 Inspect Hoses for Deterioration 3 3 Replace Impeller in Seawater Pump 3 3 Check Propeller and Shaft Alignment 3 Check and Adjust Ignition Timing Carbureted Engine Only 3 Check and Adjust Carburetor 3 Clean and In...

Page 28: ...be replaced If you cannot re use the same bolt do not improvise Performance could be sacrificed without original Marine Power parts or parts recommended by Marine Power A marine environment is a tough one Parts subjected to salt water can rapidly corrode and engine failure could result Warranty on Marine Power Engines could also be affected if other than recommended replacement parts are used Cran...

Page 29: ... engine Run for approximately 5 minutes and inspect for leaks 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 DANGER WARNING CAUTION DO NOT overfill crankcase with oil Agitation or splashing of oil may cause it to become aerat ed which will a...

Page 30: ... 5 Push new element Part 396007 on pump until click is felt 6 Replace O ring included with filter 7 Re install canister bowl on unit snug tight only 8 Two 10 second key ups should prime system Fuel Flow Schematic High Pressure Pump Outlet 60 PSI Fuel Filter Negative Terminal IN OUT Positive Terminal Low Pressure Pump is 4 7 PSI at outlet Inlet has a small screen inside fitting This screen may be f...

Page 31: ...ensioner Normally no maintenance is required Sea Water Pump Impeller Replacement Remove 4 screws from pump cover Remove cover and gasket Pry out impeller using a flat screw driver on each side of the center of the shaft Install new impeller Replace gasket cover and re tighten screws Battery Cables Multiple Engine Battery Precautions EFI The alternator is designed to charge the battery that supplie...

Page 32: ...e surge tank at all times If coolant is consistently low additional inspection for leaks in the cooling system may be required Filler Neck and Pressure Cap DO NOT remove pressure cap when engine is HOT If coolant is low add the proper mixture 50 water 50 antifreeze to the top of the filler neck located on the heat exchanger tank If coolant is consistently low additional inspection for leaks in the...

Page 33: ... Half System Air bleed is located on top of port cylinder head at the front Use a 10mm socket with 9 extension and a drive ratchet Loosen bolt holding down head bleed tube connection while engine is running Re tighten after air bubbles have stopped and only coolant is flowing out of the connection Air Bleed Location ...

Page 34: ...at 220 F Reduces RPM to 2500 Crank Sensor ECM sets code if sensor fails diagnostic test 636 X Typically won t start if code is triggered Check tightness of sensor and electrical connections EST ECM sets code if ignition coil fails diagnostic test 65541 48 X Last digit corresponds to coil number Electronic Throttle Control ECM sets code if dual sensors out of range 65604 05 X X Limits RPM to 1000 C...

Page 35: ...re ECM detects cylinder misfire 65591 99 X Last digit corresponds to cylinder number 99 is random cylinder misfire Oil Pressure Sensor ECM sets code if sensor fails diagnostic test 100 X Oil Pressure Warning Sensor alerts ECM if oil pressure is too high or low 100 X X Reduces RPM to 2500 Oil Temperature Sensor ECM sets code if sensor fails diagnostic test 175 X Oil Temperature Warning Sensor alert...

Page 36: ... buzzer alarm System Voltage ECM sets code if system voltage is below 10 or above 16 627 X Check alternator connections and for tight belt May need replacement Throttle Position Sensor ECM detects dual sensors out of range 65601 02 X X Reduces RPM to 1000 Check throttle body connector Throttle Position Sensor ECM detects dual sensors do not agree 65610 13 X X Reduces RPM to 1000 Check throttle bod...

Page 37: ...eplace Bad Starter Solenoid or Motor Replace Shift Control in Gear Take Out of Gear Faulty Starter Relay Check Relay in SSEC Box Hydro Lock Remove Spark Plug Look for Water in the Cylinder Engine Cranks But Will Not Start Possible Cause Remedy Faulty Fuel Pump Note That Low Pressure and High Pumps Are Operating Insufficient Fuel Supply Check Fuel Supply Shut Off Valve Check Fuel Filter 5 7 6 0 6 2...

Page 38: ...t Be Adequate at Wide Open Throttle at Full Load Restricted Anti Siphon Valve Remove From Fuel Tank and Verify Spring Pressure Low Compression See Dealer Engine performance can be greatly affected by boat hull and prop condition High Speed Miss Possible Cause Remedy Water in Fuel Inspect Clean Replace Clogged Fuel Filter Change Fuel Filter Insufficient Fuel Supply Approximately 60 PSI Fuel Pressur...

Page 39: ...Approximately 60 PSI Fuel Pressure Must Be Adequate at Wide Open Throttle at Full Load Poor Fuel Economy Possible Cause Remedy Boat Hull Dirty Clean Check Adjust Incorrect Prop Size or Damage Verify with Dealer or Manufacturer Clogged Flame Arrester Check Clean Replace Low Engine Compression See Dealer Engine Running Too Hot or Cold Raw Water Engines Operate at 145 F Closed Cooled Engines Operate ...

Page 40: ...n Page 15 for Correct Oil Level Erroneous Oil Gauge Readings Contact Dealer to Perform a Mechanical Oil Pressure Check Incorrect Dipstick See Dealer Incorrect Oil Viscosity or Diluted Change to Proper Oil Oil Pump Malfunctioning See Dealer Excessive Bearing Clearance See Dealer Low Oil Pressure Will Set a Trouble Code and Will Reduce Engine RPM Oil Pressure as Low as of 5 lbs at Idle is Acceptable...

Page 41: ...e Greater at Higher RPM s Engine Overheating Verify if Engine is Actually Overheating Possible Cause Remedy Low Coolant Level Add Coolant Refer to Bleeding Procedure if Coolant was Low or Not Flowing into Tank Clogged Sea Water Intake Clear Intake Ensure That All Hoses After the Intake are Clear Clogged Sea Water Strainer Clean Sea Strainer Loose Hose Connections Check and Tighten Clamps Sea Water...

Page 42: ...E 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 e...

Page 43: ...ngines CCW or Normal Rotation Right Hand Engines CW or Opposite Rotation Engine Bed The engine bed should be of horizontal design and heavily constructed to maintain engine alignment All of the thrust used in moving the boat is transferred to the hull through the engine bed The standard engine has support mounts that are intended to be used on engine beds arranged for 22 24 bolt centers Use adequa...

Page 44: ...ve emission requirements of 40 CFR part 1060 and CFR 1045 112 Any manufacturer installing a high performance engine must use enhanced evaporative control systems on any boat that is manufactured for sale sold or offered for sale in California or that is introduced delivered or imported into California for introduction into commerce Enhanced evaporative control system has designed the system compon...

Page 45: ...ure Every exhaust connection should be secured with at least 2 hose clamps The clamps should be stainless steel and at least 1 2 wide Electrical Connection NOTE Marine Power EFI engines are equipped with Smart Start this feature is common in late model automobiles but is new to the boating industry This feature enables the operator to start the engine by momentarily engaging the key switch it is n...

Page 46: ...uel pump The fuel pump must also have the supplied serviceable 100 Micron filter installed on the inlet side of the fuel pump When using an auxiliary engine such as an outboard motor never plumb or tee into the main engine fuel system The auxiliary engine shall have its own fuel pick up tube and fuel filter water separator from the fuel tank Plumbing into the main engine fuel supply will cause dam...

Page 47: ...lation Notes Installer must install aftercooler radiator and oil cooler See Special Fuel Supply instructions on page 44 Engine Harness Connections are on page 46 Coolant reservoir should be connected to the bypass loop Oil cooler connections are above oil filter on port side ...

Page 48: ...46 www MarinePowerUSA com 13 Installation Instructions Adapter Harness Note this can be used as a Trim Sender Wire ...

Page 49: ...47 www MarinePowerUSA com 13 Installation Instructions Heater Connections Heater Out Heater Out Heater In Heater In 5 7L Engine 6 0 6 2L Engine ...

Page 50: ...be a cable routed from the throttle control lever at the helm to a potenti ometer located in the engine compartment Make certain that this cable operates freely and is properly adjusted The adjustable potentiometer stop screws must not be used as the stop for the throttle lever cable assembly at the helm 6 Check the transmission shift cable lever adjust ment on Inboard V drive and stern drive appl...

Page 51: ...ate ______________________________________ Name As It Appears On the Credit Card _________________________________________________________________________________________________ Signature _______________________________________________________________________________________________________________________ Mail completed form to Warranty Registration Transfer Marine Power 17506 Marine Power Indus...

Page 52: ...ce Log SERVICING DEALERS Note If You Are Unable to Locate an Independent Servicing Dealer Please Contact a Marine Power Distributor Closest to You for Further Assistance Date Service Maintenance Performed Performed By Operating Hours ...

Page 53: ...51 www MarinePowerUSA com Service Log Date Service Maintenance Performed Performed By Operating Hours ...

Page 54: ...52 www MarinePowerUSA com Service Log Date Service Maintenance Performed Performed By Operating Hours ...

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Page 56: ...lized in any form or by any means electronic or mechanical including photocopying recording or any information storage and retrieval system without permission in writing from MARINE POWER HOLDING LLC Marine Power 17506 Marine Power Industrial Park Ponchatoula LA 70454 USA www MarinePowerUSA com ...