GM Marine Power 6.2L LS3 V8 Marine Engine Owners Manual

ENGINE OWNER’S MANUAL VERSION 3 Downloaded from www.Manualslib.com manuals search engine

i www.MarinePowerUSA.com Table of Contents SECTION 1: INTRODUCTION PROPOSITION 65..............................................................1 SAFETY WARNINGS .........................................................1 REPLACEMENT PARTS........................................................1 SAFE BOATING ................................................................2 WARRANTY................................................................ 2-5 SECTION 2: SAFE BOATING CARBON MONOXIDE EXPOSURE ...........................................6 SECTION 3: ENGINE IDENTIFICATION ENGINE TYPE ..................................................................7 MODEL SPECIFICATIONS.....................................................8 SECTION 4: ELECTRONIC SEQUENTIAL FUEL INJECTION INFORMATION ....................................................................9 SECTION 5: ENGINE ALARMS AND INSTRUMENTATION DIGITAL ALARMS ...........................................................10 INSTRUMENTATION .........................................................11 SECTION 6: SSVEC FUSE AND RELAY ENCLOSURE ....... 12-15 SECTION 7: PRECAUTIONS OIL LEVEL ....................................................................16 HYDROLOCK..................................................................16 SECTION 8: ENGINE OPERATING INSTRUCTIONS GASOLINE REQUIREMENTS................................................17 OIL REQUIREMENTS ........................................................17 STARTING ENGINE EFI ....................................................17 ENGINE BREAK-IN/25 HOUR INSPECTION...................... 17-18 SECTION 9: WINTERIZATION 4.3/5.7L RAW WATER COOLED ENGINES ..........................19 FULL CLOSED COOLED ENGINES.........................................20 HALF CLOSED COOLED ENGINES .................................. 21-22 FULL CLOSED INBOARD JET ENGINES..................................23 SECTION 10: ENGINE MAINTENANCE SCHEDULED MAINTENANCE BY OWNER...............................24 SCHEDULED MAINTENANCE BY QUALIFIED TECHNICIAN ...........25 CRANKCASE OIL CHANGE ................................................26 OIL FILTERS ..................................................................27 FLAME 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 HIGH SPEED MISS.........................................................36 FUEL SYSTEM - RICH......................................................37 FUEL SYSTEM - LEAN .....................................................37 POOR FUEL ECONOMY.....................................................37 ENGINE STARTS AND STOPS.............................................38 OIL PRESSURE - LOW .....................................................38 OIL PRESSURE - HIGH.....................................................38 EXCESSIVE OIL CONSUMPTION ..........................................39 ENGINE OVERHEATING.....................................................39 WATER IN ENGINE CYLINDER OR BASE ...............................40 SECTION 13: INSTALLATION INSTRUCTIONS ENGINE COMPARTMENT...................................................41 ENGINE MOUNTING........................................................41 ENGINE ROTATION..........................................................41 ENGINE BED .................................................................41 COOLING SYSTEM .................................................... 41-42 EMISSION-RELATED INSTALLATION INSTRUCTIONS...................42 EXHAUST PIPING............................................................42 ELECTRICAL CONNECTION .................................................43 BATTERIES ....................................................................43 DUAL ENGINES..............................................................43 BATTERY ISOLATORS........................................................43 ENGINE BATTERY SPECIFICATIONS ......................................44 BATTERY CABLE LENGTH REQUIREMENTS .............................44 SPECIAL FUEL INSTRUCTIONS FOR 6.2 550 HP ENGINES ........44 LSA AIRBOAT INSTALLATION ............................................45 ADAPTER HARNESS ........................................................46 HEATER CONNECTIONS ....................................................47 PRESTART CHECKLIST ......................................................48 WARRANTY REGISTRATION TRANSFER ................................49 SERVICE LOG ............................................................. 50-52 Downloaded from www.Manualslib.com manuals search engine

1 www.MarinePowerUSA.com WARNING DANGER 1. Introduction MARINE POWER would like to thank you again for your purchase. 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 Engine Owner’s Manual to help you as the customer. READ THIS MANUAL THOROUGHLY AND COMPLETELY before attempting to operate your MARINE POWER engine. We ask that you become familiar with the components and the maintenance schedules. If you have any questions or concerns regarding this manual or your newly purchased MARINE POWER Engine, please feel free contact your nearest MARINE POWER dealer or distributor. Proposition 65 “Safety Warnings” and additional information or instructions are used to alert the installer/operator of possible safety hazards in performing certain service or maintenance procedures incorrectly or carelessly. These “Safety Warnings” alone cannot eliminate the hazards that they signal. Strict compliance with these warning instructions while performing service and maintenance procedures, plus “common sense” 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 possibility of ﬁre or explosion hazard. operation, are major accident prevention measures. Safety Warnings Signals serious damage, failure or breakdown of equipment; severe injury or high probability of death to the user if proper precautions are not taken. This signal word is applied in extreme situations. Indicates a potential hazard which could result in personal injury. Indicates a hazard which could result in damage to equipment. Replacement Parts Use of replacement parts (i.e. automotive, after-market, etc.) in the electrical, ignition and fuel systems, which are not U.S. Coast Guard approved, could cause a ﬁre or explosion hazard and must be avoided. Always request that genuine MARINE POWER Engine replacement parts be used in any repairs or maintenance being performed on your engine(s). WARNING CAUTION DANGER Downloaded from www.Manualslib.com manuals search engine

2 www.MarinePowerUSA.com 1. Introduction Safe Boating The waterways are becoming increasingly crowded and, in order to enjoy them safely, the operator should acquaint himself/herself with safe boating practices. Boating safely and seamanship courses are offered by the following national and state organizations: • Power Squadrons • Coast Guard Auxiliary • Red Cross • State, provincial or local agencies in charge of water safety enforcement MARINE POWER recommends that all power boat operators attend one of these courses. To help locate a course being offered near you, contact Boat U.S. Foundation’s toll-free national boating safety hotline, 1-800-336-BOAT, and in Virginia, 1-800-245-BOAT. The 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 MARINE POWER HOLDING, LLC receive your WARRANTY REGISTRA- TION/SEA TRIAL form properly completed for warranty purposes and to comply with federal regulation. This registration also enables us to contact you, if it should become necessary, to change or improve the product for your protection. WARRANTY REGISTRATION MUST BE RECEIVED WITHIN 10 DAYS AFTER DATE OF PURCHASE BY FIRST OWNER. Please 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 visit our web site at www.marinepowerusa.com. Again, thanks for choosing MARINE POWER. CALIFORNIA AND U.S. ENVIRONMENTAL PROTEC- TION AGENCY EMISSIONS CONTROL WARRANTY STATEMENT Your Warranty Rights and Obligations The California Air Resources Board, U.S. E.P.A., and MARINE POWER HOLDING, LLC are pleased to explain the emission control system warranty on your Inboard engine. New Inboard engines must be designed, built and equipped to meet California and EPA’s stringent anti-smog standards. MARINE POWER HOLDING, LLC must warrant the emission control system on your Inboard engine for the periods of time listed on the next page, provided there has been no abuse, neglect or improper maintenance of your inboard engine. Your emission control system may include parts such as fuel injection system, the ignition system and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, MARINE POWER HOLDING, LLC will repair your inboard engine at no cost to you, including diagnosis, parts and labor. Downloaded from www.Manualslib.com manuals search engine

3 www.MarinePowerUSA.com 1. Introduction Manufacturer’s Warranty Coverage Owner’s Warranty Responsibilities As the Inboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. MARINE POWER HOLDING, LLC recommends that you retain all receipts covering maintenance on your inboard engine, but MARINE POWER HOLDING, LLC cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all schedule maintenance. MARINE POWER highly recommends that the selling dealer do Warranty Registration along with a completed Statement of Sea Trial in order to facilitate any warranty work necessary in the future. As the Inboard engine owner, you should however be aware that MARINE POWER HOLDING, LLC may deny you warranty coverage if your Inboard engine or part has failed due to abuse, neglect or improper maintenance or unapproved modifications. You are responsible for presenting your Inboard engine to a MARINE POWER HOLDING, LLC distribution center as soon as a problem exists. The warranty repairs will be complete within a reasonable amount of time, not to exceed 30 days. 1. MARINE POWER HOLDINGS, LLC (“Marine Power”) warrants to the first owner purchasing at retail and all subsequent owners, of every Marine Power Inboard marine engine manufactured after January 1, 2008, that the emissions control devices on Marine Power Inboard marine engines are free from defects in materials and workmanship when manufactured and will remain so for the stated period in the above table. Marine Power 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 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. The warranty shall commence, on the date of delivery to the first retail purchaser or from the date the engine is first placed in service for demonstra- tion or any other purpose prior to the sale to the first retail owner. However, in no event shall the duration of this Warranty exceed three (3) 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 Owner’s Manual will be warranted for the appropriate warranty period in the above table. If the part fails during the period of warranty coverage, the part will be repaired or replaced by Marine Power at a warranty station. Engine Type Power Electronic Mechanical Rating Components Components Conventional - OEM Less than or equal to 3 Years or 480 Hours 3 Years or 480 Hours 373 kW (500 HP) Hi-Performance - OEM Between 373 kW (500 HP) 3 Years or 150 Hours 3 Years or 150 Hours and 485 kW (650 HP) Complete Engine Repower Less than or equal to 2 Years or 300 Hours 2 Years or 300 Hours 373 kW (500 HP) Complete Engine Repower Between 373 kW (500 HP) 1 Year or 150 Hours 1 Years or 150 Hours and 485 kW (650 HP) Downloaded from www.Manualslib.com manuals search engine

4 www.MarinePowerUSA.com 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 Owner’s Manual will be warranted for the appropriate warranty period in the above table. 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 Owner’s 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 first scheduled replacement point for the part. 6. Repair 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. Warranty services and repairs will be provided at all Marine Power distribution centers and trained marine dealers. 7. The 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. 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 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. Add-on or modified parts, as defined in CCR, Section 1900 (b)(1) and (b)(10), Title 13, that are not exempted by the Air Resources Board will not be used. The 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. 12. The following parts are covered by this general emissions warranty statement. A) Fuel Metering System 1) Fuel Injectors 2) Fuel Pressure Regulator 3) Manifold Absolute Pressure Sensor 4) Throttle Position Sensor 5) Throttle Body 6) Coolant Temperature Sensor 7) Oxygen Sensors 8) Intake Valves B) Air Induction System 1) Intake Manifold 2) Air Filter/Flame Arrestor 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) Oil Pump and Internal Parts E) Positive Crankcase Ventilation (PCV) System 1) PCV Valve 2) Oil Filler Cap 1. Introduction Downloaded from www.Manualslib.com manuals search engine

5 www.MarinePowerUSA.com F) Exhaust System 1) Exhaust Manifolds and Risers 2) Exhaust Valves 3) Catalysts G) Miscellaneous Items Used in Above Systems 1) Hoses, 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 13. The repair or replacement of any warranted part otherwise eligible for coverage under this warranty may be denied from such warranty coverage if Marine Power demonstrates that the engine and/ or part has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part. 14. This Warranty will not apply to: A) Use of an accessories or parts not manufactured or sold by MARINE POWER. B) Neglect, failure to follow maintenance schedules, accident, abnormal operations, misuse, 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. 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, overloading of engine, improper gear or propeller selection, engine overheating, excessive back pressure, incorrect ignition timing, excessive total timing. F) Reimbursement for: Haul-out, launch, towing, storage charges, rental charges of any type, inconvenience of any type, loss of time or income, expense of returning a MARINE POWER product to a service facility, towing, lodging, loss or damage to personal property. G) Carburetor replacement and labor is limited to mechanical defects only. Replacement does not extend to contaminated fuel, varnish or other residues, changes in fuel mixtures, poor octane fuel or adjustments beyond ﬁve (5) hours of engine operation. 15. Marine Power reserves the right to limit 1. Introduction warranty coverage on engines that have accumulated excessive hours through commercial use or any other non-typical operation. Downloaded from www.Manualslib.com manuals search engine

6 www.MarinePowerUSA.com practices, and/or carbon monoxide poisoning on recreational boats, contact the following: National Marine Manufacturers Association (NMMA) 200 East Randolph Drive, Suite 5100 Chicago, IL 60601 312-946-6200 www.nmma.org United States Coast Guard Office of Boating Safety Chicago, IL CG Headquarters G-OPB-3 2100 Second Street, SW Washington, DC 20593 202-267-0984 www.uscgboating.org American Boat & Yacht Council, Inc. (ABYC) 3069 Solomons Island Road Edgewater, MD 21037-1416 410-956-1050 www.abyc.com 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 2. Safe Boating CAUTION Carbon Monoxide Exposure Carbon Monoxide is a odorless, colorless and taste- less gas that cannot be smelled, seen or tasted. Sustained exposure to carbon monoxide gas may lead to brain damage, unconsciousness or death. Downloaded from www.Manualslib.com manuals search engine

7 www.MarinePowerUSA.com 3. Engine Identification Every Marine Power Engine is equipped with an Engine Identification Tag, also known as a Serial Number Tag. This tag contains information (model number and serial number) that will be required before any warranty work (if necessary) can be done. Airpac: Engines configured for airboat applications. These engines use closed cooling systems with automotive style radiators. Their exhaust manifolds are dry and usually supplied by the boat builder. Enpac: Engines configured for 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 winterization. See Section 9: Winterization procedures. Towpac: Engines configured for watersport tow boat applications. Engines may be configured for conventional inboard or v-drive application. In many of these applications throttle and shift is highly integrated with the boat instrumentation Sportpac: Engines configured for traditional inboard vessels. Many of these applications are twin installations. Downloaded from www.Manualslib.com manuals search engine

8 www.MarinePowerUSA.com 3. Engine Identiﬁcation Engine Type Repower Original Equipment Unique Feature Displacement Bore & Stroke Compression Ratio Cylinder Block Cylinder Head Recommended Fuel Max RPM @ Wot Idle RPM HP Fuel Pressure LP Fuel Pressure Oil Pressure @ 2000 RPM Min Oil Pressure @ Idle Operating Temp RW Cooled Operating Temp FW Cooled Sparkplug Type Sparkplug Gap Timing @ Idle Timing @ 4000 RPM Firing Order Alternator Rating Crankcase Oil Oil Capacity Closed Cooling Fluid Closed Cooling Capacity 4.3 VORTEC MPI V6 X X n/a 4.3/262 CID 101.6 x 88.39 mm 9.4 : 1 Cast Iron Cast Iron 87 Octane 4300-4600 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 1-6-5-4-3-2 95 amps 15W-40 5 Qts. Antifreeze/Water 10 Qts. 5.7 VORTEC MPI V8 X X n/a 5.7/350 CID 101.6 x 88.39 mm 9.4 : 1 Cast Iron Cast Iron 87 Octane 5200 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 1-8-7-2-6-5-4-3 95 amps 15W-50 Jets/Monsoon: 8 Qts., Other: 6 Qts. Antifreeze/Water 10 Qts. 6.0 VVT V8 X X Variable Cam Timing 6.0L/364 CID 101.6 x 92 mm 9.6 : 1 Cast Iron Aluminum 87 Octane 5200 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 1-8-7-2-6-5-4-3 95 amps 15W-40 Jets: 8 Qts., Other: 6 Qts. Antifreeze/Water 10 Qts. 6.2 LSA V8 X X Supercharged 6.2L/374 CID 103.25 x 92 mm 9.1 : 1 Aluminum Aluminum 91 Octane 5200 ECM Controlled 65 PSI 4-7 PSI 30-60 PSI 10 PSI n/a 170-190° F 12571165 (AC 41-104) .040” ECM Controlled ECM Controlled 1-8-7-2-6-5-4-3 95 amps 15W-50 Jets: 8 Qts., Other: 6 Qts. Antifreeze/Water 10 Qts. Downloaded from www.Manualslib.com manuals search engine

GM Marine Power 6.2L LS3 V8 Marine Engine Owners Manual

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