Owner`s Manual MV10 Gen. IV Series Engines

Transcription

Owner’s Manual
MV10 Gen. IV Series Engines
Revision - 5B
August 2009
Serial #:____________________________
____________________________
ILMOR High-Performance Marine, LLC
43939 Plymouth Oaks Blvd. • Plymouth, MI. 48170 • www.ILMOR.com • (734) 456-3600
Owner's Manual
Revision - 5B
August 2009
Page 2
Owner's Manual
Revision - 5B
August 2009
Table of Contents
Welcome.......................................................................5
Safety Information.......................................................6
Contact Information ....................................................6
Emissions ....................................................................7
Owner Responsibility ........................................................ 7
Emissions Control Information Label ........................... 7
Star Label .................................................................... 8
Hang Tag ..................................................................... 9
On-Board Diagnostics – Marine (OBD-M) ...................... 11
Warranty ......................................................................... 12
Manufacturer's Warranty............................................ 12
Owner's Warranty Responsibilities ............................ 12
General Emissions Warranty ..................................... 13
Exclusions.................................................................. 13
Emission Control System Warranty ........................... 13
Mechanical Emission-Related Components Warranty 14
Electronic Emission-Related Control Parts Warranty. 14
Pre-installation Considerations:..............................15
Mounting the Engine.................................................16
Hoist Points for Engines ................................................. 16
Engine Mounting Options ............................................... 17
Bell Housing Options ...................................................... 19
Leveling the Engine ........................................................ 19
Exhaust System ........................................................20
Header Options .............................................................. 20
Exhaust Installation......................................................... 21
Fuel Injection System ...............................................22
Vapor Lock ..................................................................... 22
Components ................................................................... 23
Fuel Injection System Diagram....................................... 25
Fuel Rail Covers ............................................................. 26
Throttle Position Sensor ..........................................27
Throttle Cable and Mount ............................................... 27
Engine Cooling System ............................................28
Sea Water Plumbing....................................................... 28
Coolant Type .................................................................. 29
Capacity.......................................................................... 29
Expansion Tank ......................................................... 29
Cooling System Bleed Screw..................................... 29
Filling the Coolant System .............................................. 30
Power Steering System ............................................31
Electrical System ......................................................32
Fuse Box ........................................................................ 33
Fuse box Cover Removal .......................................... 33
Power Distribution & Fuse Box Layout....................... 33
Boat/Engine Interface Wiring .......................................... 34
Engine Configuration Overview ...................................... 35
Diagnostic Tools ............................................................. 35
Engine Configuration ...................................................... 36
Trim Angle Configuration ................................................ 38
Instrumentation............................................................... 40
Optional Instrumentation............................................ 40
Sensor Layout................................................................. 41
Sensor Torques.......................................................... 41
Engine Monitoring Alarm System – MIL.......................... 42
Water temperature ..................................................... 42
Oil pressure................................................................ 42
Oil temperature .......................................................... 42
Basic Engine Operation ........................................... 43
Prior to Start Procedures ................................................ 43
Oil Level (HOT) .......................................................... 43
Starting the MV10 ........................................................... 44
Stopping the Engine........................................................ 45
Engine Break-in .............................................................. 45
Special Precautions ................................................... 45
Leakdown test................................................................. 46
Fuel Requirements ................................................... 47
Warranty Information.................................................. 47
Gasoline containing Alcohol ....................................... 47
Maintenance .............................................................. 48
Engine Oil ....................................................................... 48
Warranty Information.................................................. 48
Oil Capacity................................................................ 48
Oil Removal................................................................ 48
Engine Coolant ............................................................... 49
Coolant Type.............................................................. 49
Capacity ..................................................................... 49
Power Steering Fluid....................................................... 49
25 Hour Service .............................................................. 50
Rebuild Schedule............................................................ 50
Winterization ................................................................... 51
Ignition System ............................................................... 52
Spark Plugs................................................................ 52
Engine Torque Specifications ......................................... 52
Maintenance Schedule ................................................... 53
Replacement Intervals .................................................... 54
Engine Specifications .............................................. 55
Appendix I - MV10 Diagrams ................................... 56
MV10 - DRIVE BELT ROUTING ..................................... 56
MV10 - Front View .......................................................... 57
MV10 - Port Side............................................................. 58
MV10 - Starboard Side ................................................... 59
Appendix II - MV10 Service Parts Listing ............... 60
Appendix III – OBD-M Trouble Codes..................... 61
Appendix IV - Wiring Schematics ........................... 64
Power and Ground Wiring............................................... 64
NMEA 2000 / CAN Connection - Boat - MV10, Dual
Engine Layout ................................................................. 65
Engine - Dash Connections ............................................ 66
Engine - Helm Cable Terminations Diagram................... 67
Engine - Helm Cable Terminations Photo ....................... 68
NOTES ....................................................................... 70
Maintenance Log ...................................................... 71
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Owner's Manual
Revision - 5B
August 2009
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Owner's Manual
Revision - 5B
August 2009
Welcome
ILMOR High-Performance Marine would like to thank you for selecting the MV10 for your boating needs.
The MV10 engine represents a new opportunity for the boating world to enjoy a reliable, high performing
power-plant. Based on a lightweight, high-output V10, the concept of this engine package is to deliver highperformance boating pleasure without the typical complications. Along with its high power and torque output,
the MV10 is notable for its smooth acceleration, ease of handling, reduced fuel consumption, excellent
drivability and user friendly character.
PLEASE READ THIS MANUAL PRIOR TO INSTALLING
OR OPERATING THE ENGINE(S).
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Owner's Manual
Revision - 5B
August 2009
Safety Information
Throughout this manual there are safety warnings and notes which point out the hazards of performing
maintenance and service procedures in a careless or incorrect manner. These warnings alone cannot cover
every possible procedure in which a service might be performed or the dangers involved with such procedures.
Please pay strict attention to all warnings while performing any service and take caution to ensure that neither
the person performing the service, nor the product being serviced will be damaged by the selected procedure.
It is the responsibility of the owner / operator(s) to perform all safety checks to the engine(s) before operating the
boat. When properly adhered to, all maintenance and lubrication schedules will ensure the long life and
performance of your MV10 engine. When service and maintenance are required, please return the boat to an
ILMOR High-Performance Marine dealer or authorized ILMOR service center.
All information, illustrations, and specifications covered in this manual are based on the latest product
information available at the time of publication. Product information is subject to change without notice. Please
contact ILMOR High-Performance Marine for technical bulletins and updates to your MV10 owner's manual.
WARNING
All fasteners used on the MV10, unless otherwise specified, are METRIC and include a number of
special or non-standard fasteners. Only use fasteners which have been supplied or approved by
ILMOR High-Performance Marine.
WARNING
Use only genuine ILMOR High-Performance Marine replacement parts. Many of the electrical and
ignition components have been designed to comply with U.S. Coast Guard regulations intended to
minimize the possibility of fire and / or explosion. The use of non approved replacement parts from
aftermarket sources could result in fire and / or explosion and loss of warranty coverage. Please
refer to the appendix of this manual for Ilmor High-Performance Marine replacement part numbers.
Contact Information
To contact ILMOR High-Performance Marine directly, please forward any inquiries to the following address. We
can also be reached by phone, fax, or e-mail. If contacting via mail, fax, or e-mail please send to the attention
of: ILMOR High-Performance Marine - Sales & Service
ILMOR High-Performance Marine LLC.
43939 Plymouth Oaks Blvd.
Plymouth, MI 48170
Phone: (734) 456-3600
Fax:
(734) 456-3699
sales&[email protected]
For product updates and technical bulletins please visit us on the web:
http://www.ILMOR.com
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Owner's Manual
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August 2009
Emissions
Owner Responsibility
It is the responsibility of the owner / operator(s) to have routine engine maintenance performed in order to
maintain emission levels within the certified standards.
The owner / operator(s) are not to modify the engine in any manner that would alter the allowable emission levels
to exceed their certified specifications.
Emissions Control Information Label
Each engine is affixed with a tamper-resistant Emission Control Information label at the time of manufacture by
ILMOR High-Performance Marine. This label affirms the required emissions statement, along with the engine
family, and the engine displacement. The engine serial number and the date of manufacture (MMDDYY) will be
stamped on the block between the front mount and the oil line. Boat builders and dealers may not remove the
labels or the parts they are affixed to prior to sale. If replacement decals are needed, please contact ILMOR
High-Performance Marine prior to engine installation or sale.
Engines that are marked with a CE label affirm that the Declaration of Conformance applies. The Declaration of
Conformity attests the engine’s conformance to the appropriate European Community Directive. The CE label
will be located on the back of the heat exchanger.
Fig. 1 Emission Control Information Label
Fig. 2 CE Label
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Owner's Manual
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August 2009
Star Label
Beginning January 1, 2009, one (5” x 6”) Three Star label will be included with each certified ILMOR HighPerformance Marine engine. For any boat which will be sold or registered in California, the Three Star label must
be affixed to the port side of the hull either before or after the vessel registration number, as shown below.
ILMOR High-Performance Marine recommends that the Three Star label be affixed to all boats, regardless of the
location of sale or registration.
Fig. 3 Star Label Location
All ILMOR High-Performance Marine (MV10 Gen. IV) engines will have a Three Star – Ultra Low Emission rating.
This indicates that the engines have 65% lower emissions than One Star – Low Emissions engines. The Three
Star label identifies these engines to meet the California Air Resources Board’s Sterndrive and Inboard marine
engine 2009 high-performance exhaust emission standards. This label will also be located on the back of the
heat exchanger, near the CE label.
Fig. 4 Three Star - Ultra Low Emissions Label
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Owner's Manual
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August 2009
Hang Tag
WARNING
The hang tag is the responsibility of the Dealer. The Dealer must mark the correct box on each hang
tag to match the Star label on the engine and the boat. The Dealer must display the hang tag in a
visible location on the boat prior to displaying the boat for sale in California. If only the engine is
displayed, a hang tag must still be placed in a visible location on the engine. Failure to correctly
display the hang tag may result in a citation and possible fine to the dealer from the California Air
Resources Board.
Fig. 5 Front Side of Hang Tag
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Owner's Manual
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August 2009
Fig. 6 Reverse Side of Hang Tag
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Owner's Manual
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August 2009
On-Board Diagnostics – Marine (OBD-M)
All MV10 Gen. IV engines are equipped with marine on-board diagnostics to comply with the 2009 California
mandated OBD-M diagnostic specification.
The Malfunction Indicator Lamp (MIL) will appear on the dash when system problems occur on the boat. If the
MIL is set due to an emissions related fault, a Diagnostic Trouble Code (DTC) will set.
The MIL has the following functions:
- To notify the operator that a problem has occurred, so the owner / operator can arrange for service as
soon as possible.
- To display DTC’s that have been stored due to a system malfunction, in order to help the technician
diagnose system problems.
If the MIL is set, please contact ILMOR High-Performance Marine or an authorized service center to arrange a
diagnostic scan at the earliest possibility.
The DTC(s) are stored in the Ilmor Controlled Electronics (ICE) unit's memory and can be retrieved with an
ILMOR High-Performance Marine version scan tool or through Diacom PC Software.
A handheld scan tool is available directly from ILMOR High-Performance Marine. The Diacom PC Software can
be obtained by contacting Rinda Technologies at (773) 736-6633 or by visiting http://www.rinda.com.
The Diagnostic Scan Tool will be connected to the Data Link Connector (DLC); a flat 6 pin connector. The
connector is located on the port forward section of the intake manifold and is usually marked with either DLC or
Data Link Connector just behind the plug. Note that the protective DLC cover must be removed prior to
connecting the Scan Tool, and the ignition switch must be turned to the “ON” position, but do not start the engine.
Reference Appendix III – OBD-M Diagnostic Trouble Codes, in this manual or the manufacturer’s Scan Tool
Manual for a listing and description of DTC’s.
Fig. 7 Data Link Connector
NOTE: When connecting to a multiple engine configuration in which all engines are on the same NMEA 2000
CAN BUS, care must be taken to ensure that the user is communicating with the correct engine. In this situation,
plugging into any DLC allows communication to any engine. Confirm that you are communicating with the
expected engine by moving the throttle assembly and seeing that parameter move on the diagnostic tool.
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Owner's Manual
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August 2009
Warranty
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and ILMOR High-Performance Marine are pleased to explain the emission
control system warranty on your 2009 sterndrive/inboard engine. In California, new sterndrive/inboard engines
must be designed, built and equipped to meet the state’s stringent anti-smog standards. ILMOR HighPerformance Marine, LLC must warrant the emission control system on your sterndrive/inboard engine for the
periods of time listed below, provided there has been no abuse, neglect or improper maintenance of your
sterndrive/inboard engine.
Your emission control system may include parts such as the carburetor or fuel injection system, the ignition
system, and catalytic converter. Also included are selected emission-related hoses, belts, connectors and
assemblies.
Where a warrantable condition exists, ILMOR High-Performance Marine, LLC will repair your sterndrive/inboard
engine at no cost to you, including diagnosis, parts and labor.
Manufacturer's Warranty
Select electronic emission-related control parts from model year 2009 and later sterndrive/inboard engines are
warranted for 3 years or 480 hours, whichever occurs first. Select mechanical emission-related components are
warranted for 1 year or 50 hours of operation, whichever occurs first.
Warranty coverage based on the hourly period is only permitted for engines that are equipped with hour meters
as defined in § 2441(a)(13) or their equivalent. If any emission-related part on your engine is defective under
warranty, the part will be repaired or replaced by ILMOR High-Performance Marine, LLC.
Owner's Warranty Responsibilities
As the sterndrive/inboard engine owner, you are responsible for the required maintenance listed in your owner’s
manual. ILMOR High-Performance Marine, LLC recommends that you retain all receipts covering maintenance
on your sterndrive/inboard engine, ILMOR High-Performance Marine cannot deny warranty solely for the lack of
receipts.
ILMOR High-Performance Marine, LLC may deny you warranty coverage if your sterndrive/inboard engine or a
part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
You are responsible for presenting your sterndrive/inboard engine to an ILMOR High-Performance Marine, LLC
service center as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of
time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you should contact ILMOR HighPerformance Marine, LLC at 1-734-456-3600.
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Owner's Manual
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August 2009
General Emissions Warranty
ILMOR High-Performance Marine must warrant that the engine is:
Designed, built, and equipped so as to conform 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 free
from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material
respects to that part, as described in the engine manufacturer’s application for certification.
Exclusions
Failures other than those resulting from defects in material or workmanship are not covered by this warranty.
This warranty does not extend to emission control systems or parts which are affected or damaged by owner
abuse, neglect, improper maintenance, misuse, misfueling, improper storage, accident and/or collision, the
incorporation of, or use of, unsuitable attachments, or the unauthorized alteration of any part.
This warranty does not cover the replacement of expendable maintenance items made in connection with
required maintenance service after the item’s first scheduled replacement as listed in the maintenance section of
the product Owner’s Manual, these products include, but are not limited to spark plugs and filters.
DISCLAIMER: This warranty is applicable only where the California emission control system warranty regulation
is in effect.
Emission Control System Warranty
ILMOR High-Performance Marine, LLC will warranty mechanical emission-related components for 1 year or 50
hours of operation, whichever occurs first; and electronic emission-related control parts for 3 years or 480 hours,
whichever occurs first.
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Owner's Manual
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August 2009
Mechanical Emission-Related Components Warranty
Systems Covered by this Warranty:
Parts Description:
Fuel Metering
Pressure regulator
Intake valves
Intake manifold
Air filter*
Spark plugs*
Ignition coil
Oil pump (includes internal parts)
PCV valve
Oil filler cap
Exhaust manifold (tailpipe not included)
Exhaust valves
Carbon canister
Fuel tank
Low-permeation hoses
Hoses
Clamps
Fittings
Tubing
Sealing gaskets or devices
Mounting hardware
Pulleys
Belts
Air Induction
Ignition
Lubrication
Positive Crankcase Ventilation (PCV)
Exhaust / Thermal Reactor System
Evaporative
Miscellaneous Items **
* Covered up to the first required replacement only. See the Maintenance Schedule in the Owner’s Manual.
** Covers emissions related components only.
Electronic Emission-Related Control Parts Warranty
Systems Covered by this Warranty:
Parts Description:
Fuel Metering
Ignition
Miscellaneous Items
Fuel injectors
Electronic ignition system
Camshaft position sensor
Crankshaft position sensor
Engine coolant temperature sensor
Intake air temperature sensor
Knock sensor
Manifold absolute pressure sensor
Throttle position sensor
Electronic Control Unit
Electronic Throttle Control
Note: This list applies to parts supplied by ILMOR High-Performance Marine and does not cover parts supplied
by the equipment manufacturer. Please see the original equipment manufacturer’s emissions warranty for nonILMOR parts.
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Owner's Manual
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August 2009
Pre-installation Considerations:
Provision for a MIL (Malfunction Indicator Lamp) is required for each engine on the dash. The placement should
correspond to the placement of the respective engine in the boat and must be clearly visible while piloting the
boat. Failure to properly install a MIL will result in void of the manufacturer's warranty.
Gauges must be analog or analog compatible NMEA 2000 style.
5/8” ID inlet tubes in the fuel tank.
5/8” ID tubing feeding the engine fuel inlet.
3/8” ID return fittings in the fuel tank. These should be placed such that return fuel does not aerate the inlet fuel.
All hose used for fuel delivery must meet or exceed specification in USCG regulations sec.183.540 for
recreational boating. Additionally, all fuel hose must meet the 15g/m^2 limit for fuel permeation.
Full time ‘clean power’ connection made at the isolator switch, providing power to the engine electronics
whenever the isolator is ‘ON’. This wiring should be 16 gauge.
Power should be applied from the isolator switch to the starter post using single ought (1/0) cable.
A power ground should be made at the rear of the engine directly to the battery negative terminal using single
ought (1/0) cable.
An additional electronics ground is required and should be made from the 1-pin black Ladd quick disconnect,
directly to battery negative using 6 gauge wire.
Multiple batteries must have grounds linked using single ought (1/0) gauge wire.
Pin A on the 14-pin Engine Interface is to provide power to the ignition and start switch functions on the dash.
Any other current requirements must use a relay so that the net draw from pin A is no more than that required to
operate the relay.
Provide sufficient engine compartment cooling such that engine compartment is never more than 10C (50F)
hotter than ambient.
Install water pickups. Water pickups should be located so that an uninterrupted, solid stream of water will flow
past them while the boat is in motion. Pickups should have a shutoff valve located just on the inside of the boat
and be connected to the sea strainer.
Install a sea strainer. This will require a shutoff valve at the pass-through in the hull of the boat for the seawater
inlet and one just prior to the sea-strainer within easy reach. This will make clearing the sea strainer possible.
NMEA 2000 networks will require proper wiring of the CAN stream. See electronics section.
NOTE: All engines sold for use in California will require proper installation of evaporative components including
carbon canisters. The installation of these components is the responsibility of the boat builder as per ILMOR
High-Performance Marine specifications and guidelines. It is the engine installers' responsibility to obtain the
appropriate documentation from ILMOR High-Performance Marine.
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Owner's Manual
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August 2009
Mounting the Engine
Hoist Points for Engines
NOTE:.Care must be taken when inserting bolts as to not damage the threads in the aluminum cylinder head. A
lifting strap and two "S" hooks should be used to lift the engine. An "endless" strap with a length of 5 ft. and load
bearing capacity of 5,000lb is recommended, all other hooks, cranes and rigging must have a load capacity of at
least 1,000lb.
WARNING
Port Lift Point - The port lift point on the MV10 is provided by lifting
eye PN: PE01012C. This mount attaches to the port side of the
intake manifold. For engines without a transmission, the lifting eye
should be between the 2nd and 3rd runners. For engines with a
transmission the eye should be located between the 3rd and 4th
runners.
Fig. 1
Starboard Lift Point - The starboard lift point on the MV10 is
provided by lifting eye PN:PE01012C. This mount attaches to the
starboard side of the intake manifold between the 2nd and 3rd
runners.
Fig. 2
The "S" hooks should be inserted into the lifting eyes with the strap connecting them over the crane attachment.
Care must be taken when lifting the engine or damage to the engine and accessories may occur.
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August 2009
Engine Mounting Options
The MV10 is supplied with motor mounts which allow installation into typical V-hulls and catamarans, with single
or multiple engine configurations. All views are shown from the stern of the boat facing the bow.
Standard Front Plate (PE00575)
Stringer mounting hole spacing: 20.2” centered.
This mount fits the majority of v-hulls and catamarans
available with a two stringer set-up and can be used for single
or multiple engine applications.
Standard Rear Plate (PE00452)
For use in applications where a driveshaft or an unsupported
transmission will be used.
Center Front Plate (PE00671)
Stringer mounting hole spacing: 31” centered.
This mount is typically used for single engine
boats and triple engine boats where the center
engine is mounted forward.
Center Rear Plate (PE00708)
Stringer mounting hole spacing: 31” centered.
This mount is reinforced to control front to rear engine
motion. This mount is typically used for single or triple
engine boats, where the center engine is mounted forward
and/or is utilizing a driveshaft or unsupported transmission.
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Staggered Front (PE00562, PE00563)
Stringer mounting hole spacing: From crankshaft, 6.9” (low side) & 14.9” (high side).
Typically used on twin
engine v-hull applications
with space limitations
requiring one engine to
be mounted forward
of the other (staggered).
A drive-extension kit must
be used with the forward
engine, typically referred to
as a “driveline” setup.
Staggered Rear (PE00566)
Stringer mounting hole spacing: From crankshaft, 6.9” (low side) &
14.9” (high side).This mount is reversible, use the same plate for
both sides.
Side-by-side Front (PE00528, PE00529)
Stringer mounting hole spacing: From Crankshaft, 13.5” (low side)
& 12.5” (high side).
Foot Mount, 2 required (PE00524)
Common mounting system through the use of individual
mounts on each side of the engine. These mounts use a ¾”
diameter vertical stud and fit the majority of boat/engine
combinations with two stringers.
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August 2009
Bell Housing Options
"Mercury" style (PE01025)
This bell housing features two rear mounting bosses designed to pick
up the standard inner transom plate used with several “Mercury” style
drives.
Transmission style (PE00897)
This bell housing is intended for use with the ILMOR HighPerformance Marine INDY® Transmission, it can also be used with
Series 72 gearboxes, in either direct mount or driveshaft out- drive
configurations. The rear of the engine must be supported by an
engine plate or a transmission mounted support in applications
utilizing a driveshaft.
Leveling the Engine
When leveling the engine, the best reference surfaces are the tops of the fuel rails, as they run parallel to the
crankshaft.
Fig. 3
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Owner's Manual
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August 2009
Exhaust System
Header Options
Straight Back Headers are offered as the standard exhaust option on the MV10 (Fig. 1). This standard exhaust
accommodates a large variety of applications including single and multiple engine installations.
Fig. 1 Straight Back (PE00922)
Down-Turned (Fig. 2) and High-Rise (Fig. 3) headers are both available for applications where additional
clearance, special tailpipe routing, or staggered / multiple engine installations are desired.
Fig. 2 Down-Turned (PE01260)
Fig. 3 High-Rise (PE01261)
NOTE: Part numbers given are for pairs of headers. Individual headers are available at special request,
contact ILMOR High-Performance Marine for further details.
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Exhaust Installation
Great care should be taken when installing headers onto the engine. The cylinder heads are made of aluminum
and the threads could strip if the bolts are misaligned or over-tightened. Begin by loosely installing all the
hardware, and then draw the header in evenly by tightening all bolts at gradually higher levels.
For information concerning custom tailpipes, please contact your local marine service center or boat builder.
Care must be taken to provide adequate clearance between the tailpipes and the transom. If the tailpipes
interfere with the transom they can put excessive load into the header causing cracking, premature failure, and
possible engine damage.
The headers provided with the MV10 connect to tailpipes with 4-1/2” sweeper flex flare clamps that are available
directly from ILMOR High-Performance Marine or an ILMOR authorized service center.
MV10 tailpipe clamps are available for purchase under the following part number:
-MVP 0169 (Clamp kit includes clamp, tailpipe jumper hose, hose clamps, gasket, t-bolt & nut)
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August 2009
Fuel Injection System
The fuel pump supplies fuel to the engine at a regulated pressure, great care must be taken with all items in the
fuel system to avoid leaks. Leaks could lead to a gasoline fire in the engine compartment.
WARNING
All fuel system plumbing must be in accordance with US Coast Guard (USCG) regulations using
hose which meets or exceeds SAE Standard J1527 DEC85.
All hose used for fuel delivery must meet or exceed specification in USCG regulations sec.183.540
for recreational boating. Additionally, all fuel hose must meet the 15g/m^2 limit for fuel permeation.
Each MV10 is supplied with a complete fuel delivery system installed. Components include: fuel pump, fuel
cooler, vapor-lock valve, high pressure fuel filter, and a fuel filter head with fuel/water separating filter and fuel
pressure regulator. The fuel tank should be specified to have a 5/8” (minimum) inlet tube. A 5/8” I.D. supply line
must be plumbed from the fuel tank to the input of the water separator and a 3/8” I.D. return line must be run
back to the fuel tank. Warranty coverage may be denied if a tank inlet tube or fuel supply line smaller than 5/8”
I.D. or fuel return line smaller than 3/8” I.D is used. Should you have any questions regarding fuel system
installation, immediate technical assistance is available from ILMOR High-Performance Marine.
All fuel system components supplied with the MV10 have been selected for best performance. Failure to use the
supplied components could lead to engine failure or possibly fire. Use of non-ILMOR supplied components is
done entirely at the owners’ own risk. Warranty coverage may be denied if the engine(s) are modified in any
way, by any person after delivery by ILMOR. This includes the use of non-ILMOR specified service parts unless
such modification or use of parts is requested and approved by ILMOR in writing.
Please contact ILMOR High-Performance Marine before altering the fuel delivery system in any way.
Vapor Lock
Vapor lock is primarily caused by high engine compartment temperatures, engine compartment temperature
rises to a maximum when idling in gear after high speed running.
ILMOR High-Performance Marine has put great effort forward to make the MV10 Gen. IV engine package as
robust to vapor lock as possible, but preventing vapor lock must start with the design of the boat. The engine
compartment inlet and outlet ducting must be such that a high volume of air naturally washes over the entire
engine compartment with forward motion.
Bilge blowers should be adequately sized and used whenever the engine is running (in addition to the required
running prior to engine start). If vapor lock during in-gear idling occurs, the operator should partially raise the
engine hatch. This will aid in reducing engine compartment temperature by increasing air flow.
NOTE: Fuel purchased in colder climates is blended with a higher vapor pressure than in hot climates. This is
done to promote quick starts in those regions, but as a tradeoff is much more prone to vapor lock. If possible,
avoid filling your tank in cold climates before boating in warm areas.
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Owner's Manual
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August 2009
Components
Fuel Filter Head
Fuel supply from the tank must be run directly to the fuel filter head. The filter
head is located near the rear of the engine on the port side. All fuel supply
lines to the suction side of the fuel filter head must be a minimum of 5/8”
inside diameter.
Fuel Cooler
Fuel flows from the inlet of the fuel filter head/ water separator
to the fuel cooler and then to the fuel pump. The fuel cooler
receives water directly from the sea pump.
Fuel Pump
The fuel pump is mounted on the bottom of the engine under the oil pan and is
connected to the Ilmor Controlled Electronics (ICE) unit by an interchangeable Ladd
connector or "pigtail". The MV10 utilizes a “Smart Start” strategy for safety and is
controlled via the ICE unit. When turning the ignition key to ON or START, the pump
will run to prime the fuel system and then stand-by until the engine starts. The fuel
pump will remain on while the engine is running and when the engine stops running the
ICE unit will automatically shut the fuel pump off.
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Anti-Vapor Lock Valve
The anti- vapor lock valve directs fuel vapors to the tank while allowing
high pressure liquid fuel to flow to the fuel filter and fuel rails.
High Pressure Fuel Filter
The high pressure fuel filter accepts liquid fuel from the
anti-vapor lock valve and removes any remaining particles
prior to distribution to the fuel rails.
Fuel Rails
The fuel rails are fed from the high pressure fuel filter
output using a quick-release fitting and a combination of
hard line and USCG approved fuel line. The fuel rails are
connected under the intake manifold through the use of
the crossover pipe. Excess fuel is sent back to the filter
head and is then returned to the tank.
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Fuel Injection System Diagram
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Fuel Rail Covers
The fuel rail covers are mounted to the engine by three rubber grommets. To remove the covers, grasp the back
edge in the center of the cover as shown. With light, yet steady pressure and pull directly forward. Repeat this
process on the ends of the cover. To re-install, apply soapy water to each of the three grommets. Align grommets
to the mounts and press on. Do not use oil or grease.
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Throttle Position Sensor
Throttle Cable and Mount
The MV10 is provided with a mount and fastener that are suitable for use with industry standard 33C Series
Teleflex Morse cables. The throttle position sensor is located at the rear of the engine and is attached to the
starboard side of the bell housing.
NOTE: 33C indicates a Teleflex-Morse 30 series clamp type cable with a 3" travel.
Visit http://www.teleflexmorse.com for contact or product information.
To ensure proper throttle operation and response, the following criteria must be met:
- The movement of the throttle cable during operation should be
smooth and free of binding. This applies both prior to and after
installation.
- The movement of the throttle arm on the pedal bracket must be free
of any obstructions and must never strike the stops when the cable is
attached.
- The fastener used to attach the throttle cable to the throttle arm
should have red loctite 271 applied prior to final assembly.
NOTE: When fully warm, the engine will idle at 800 rpm and is
electronically controlled via the ICE unit.
WARNING
The throttle position sensor may not be removed from the engine or installed in any other
manner without written consent and/or inspection by ILMOR High-Performance Marine.
Doing so may result in a void of the manufacturer's warranty.
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Engine Cooling System
The MV10 is supplied with a closed cooling system very similar to a traditional automotive application.
However, a heat exchanger uses seawater to extract heat from the coolant in place of a radiator.
Sea Water Plumbing
The boat must be fit with thru hull water pickups. The pickups must accommodate 1-1/4"(32mm) ID hose and
be large enough to provide the cooling system with adequate water flow. The pickups must be positioned in
area where they will receive an uninterrupted stream of water while the boat is in motion and will supply a
positive pressure to the cooling system under normal operation. The inside of the boat should be fitted with a
properly sized shutoff valve that will not restrict water flow during operation.
The sea water system should also be fitted with a high capacity sea strainer to remove debris from entering the
external cooling system. The sea strainer should be positioned in area where it is easily inspected and cleaned.
Failure to install a sea strainer will accelerate the deterioration of the heat exchangers, leading to engine
overheating and possible premature failure. Even with a sea-strainer, the covers of the fuel, oil, and coolant
heat exchangers should be removed for inspection when performing the annual service.
1-1/4” ID high pressure hose must be used to connect the water pickups to the sea strainer and to the raw
water pump inlet. Using a smaller hose will restrict cooling water flow to the engine and heat exchangers which
could lead to engine overheating and premature failure.
NOTE: Engine failure due to overheating is not covered under the warranty.
It is important to monitor the seawater pressure. At full speed, the seawater pressure must be in the range
listed in the specifications table in the index.
NOTE: Sea-water pressure measurement is provided as a standard item using a sensor mounted in the rear of
the oil/transmission oil cooler.
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Coolant Type
Only use coolant approved by ILMOR High-Performance Marine, as listed in “Engine Specifications” section.
A 50/50 solution of coolant and distilled water is suggested for optimal performance to prevent corrosion within
the engine and preserve the water pump seals.
Capacity
See “Maintenance – Engine Coolant”
Expansion Tank
To ensure the engine remains completely filled with coolant, the engine has
been fitted with an expansion tank. The tank is located on the front of the
engine directly above the alternator. See engine diagrams for further
information.
Cooling System Bleed Screw
An air bleed screw is provided near the front of the
engine on top of the thermostat housing. During the
initial fill, this bleed must be cracked open. You may
wish to attach a ¼” ID clear hose to the bleed screw to
prevent coolant from contacting the accessory drive
belt. Failure to open the bleed screw during fill will
result in air pockets and thus an incomplete fill of the
system. Close the bleed screw when a steady stream
of coolant appears.
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Filling the Coolant System
To fill the coolant system, begin by removing the pressure cap located on the heat exchanger at the front of the
engine and fill through the filler neck. Once the heat exchanger is completely filled, wait three minutes while the
system continues to settle. Fit a hose to the air bleed so that coolant will not spill onto the engine and open the
air bleed until a steady stream of coolant comes out. Carefully tighten the bleed screw. Top off the coolant until
the heat exchanger is completely full and then re-install the pressure cap. Fill the expansion tank so that the
level in the tank is just visible (as indicated by the sight tube). Check the coolant level in the tank several times
following the initial fill as air pockets and entrapped air will migrate to the tank during the first several heat
cycles.
WARNING
Before starting the engine, be certain that the sea water pump has an ample supply of cooling
water either from a hose or by placing the boat in the water with each water pick-up fully
submerged. Also, be sure all other fluids are at the proper level prior to starting. Damage caused
by overheating or running the engine without proper water flow is not covered in the
manufacturer's warranty.
Once the engine cooling system is filled, start the engine and observe the water temperature as the engine
warms. The coolant temperature should continue rising until it reaches 170º F / 77C. With the engine idling, the
thermostat should control engine temperature to approximately 170º F / 77C at all times.
If the temperature rises beyond 180º F / 82C there is most likely air trapped within the system. Shut down the
engine and allow it to cool completely. Repeat the filling procedure as described above making every effort to
get the system completely filled with coolant. Repeat these procedures until a stable 170º F / 77C reading is
achieved.
During normal operation, coolant will expand with temperature, flow out into the recovery tank and be drawn
back into engine as it cools.
The coolant expansion tank should be filled so that the sight glass is to the half way point.
WARNING
When hot, pressure builds up in the cooling system. To prevent injury, the pressure cap should
never be removed while the system is hot or under pressure.
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Power Steering System
The MV10 is supplied with one of two power steering pumps. Single engine applications require a pump with an
integrated reservoir, while multiple engine applications require a pump and a remote reservoir.
Full plumbing details of the power steering system should be obtained from the helm manufacturer.
The power steering pump on the MV10 has two connections that need to be made prior to use. High pressure
power steering supply fluid flows out of the -6AN steel fitting located on the pump housing through the filter and
to the helm. The hydraulic lines used on the high pressure side of the system must be of the type specifically
intended for use in power steering systems and should be capable of withstanding 2,000 psi.
The returning fluid is plumbed through the cooler by means of the supplied -6AN fittings on the power steering
cooler body attached to the lower left side of the engine block.
A
POWER STEERING COOLER
A – Power steering cooler return line to the
power steering reservoir.
B – Power steering system fluid from helm.
B
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Electrical System
The electrical system on the MV10 is a 12 volt negative ground system. Any attempt to connect the battery in a
reverse polarity manner could lead to extensive damage of the electronics. Any damage which occurs as the
result of reverse polarity will not be covered by the manufacturers’ warranty.
Battery positive (+) connects at starter motor battery post.
Battery negative (-), or ground, connects to the stud at the engine bell-housing.
The positive post of the battery is connected to the large post provided on the starter motor with marine grade
single ought (1/0) starter wire and appropriate eyelet. Once this connection is made, all other positive engine
circuits will be connected to battery positive from this junction. The supplied heavy rubber boot (red) must be
used on the starter motor terminal to shield the terminal and prevent accidental contact.
WARNING
When connecting the battery cables, always connect the positive (+) battery cable first.
Once the positive battery cable is connected, then the negative (-) battery cable can be
attached. This minimizes the possibility of electrical contact. Always disconnect the
negative battery cable first.
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Fuse Box
Fuse box Cover Removal
The Fuse box cover is mounted to the engine by
three rubber grommets. To remove the front
cover, begin by grasping the back edge of the
cover as shown. With light, yet steady pressure
pull directly forward. This will release the
grommets from the engine-side mounts. Any
twisting motion will increase the chance of
damage. To re-install, apply soapy water to each
of the three grommets. Align grommets to the
mounts and press on. Do not use oil or grease.
Power Distribution & Fuse Box Layout
Fuse Description
1.) Ignition Power
2.) ASD1 Power
3.) ASD2 Power
4.) Fuel Pump Power
5.) Starter Solenoid
6.) Dash Gauges
7.) ECU "Clean" Power
8.) Dash Low Currents
9.) ASD Relay Control
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Boat/Engine Interface Wiring
The electrical system of the MV10 is a mostly self contained, pre-assembled unit. The interface with boat wiring
follows established practices and conforms to regulatory guidelines. Every effort has been made to make the
electrical connection “plug and play” so that minimal to no reworking of the established wiring will be required
when rigging an MV10 engine. For wiring schematics please refer to Appendix IV of this manual.
.
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Engine Configuration Overview
The INDY® drive is fitted with sensors to monitor the trim angle and oil pressure of the outer drive unit, as well
as the neutral safety switch and oil temperature on the transmission. These sensors can be connected to the
ILMOR Controlled Electronics (ICE) engine control module and displayed on an analog style gauge or
NMEA2000 / SAE J1939 compatible display. These components should be configured at the same time as the
engine in order to ensure that all components are assigned to the correct engine position. Assigning the
correct engine position is critical, as it ensures the ICE unit communicates with the correct engine / drive and
will aid in diagnosing trouble codes.
NOTE: Trim angle indication done through an ILMOR gauge cannot be driven by a cable and must be fed from
the ICE unit
Diagnostic Tools
Engine Configuration must be done with one of two ILMOR High-Performance Marine compatible diagnostic
tools, the ILMOR High-Performance Marine scan tool (Fig. 1) or Diacom PC software (Fig. 2). When using the
scan tool, a brief description of the key functions is provided in (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
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Engine Configuration
In order to configure the engines when first installed in the boat:
1. Connect the scan tool to the Data Link Connector (DLC) (Fig.4).
NOTE: If the boat is wired for NMEA 2000 CAN BUS, you can communicate with any engine from any
DLC.
The DLC is located on the port forward section of the intake manifold and is usually marked with either
DLC or Data Link Connector just behind the plug. (Fig. 5) Note that if a cap is on the DLC it must be
removed prior to connecting the Scan Tool connection.
Fig. 4
Fig. 5
2. Turn the ignition ON for the engine that is having its location in the vessel programmed, and select the
correct ECU type from the menu (Ilmor - MV10 650 and MV10 725).
3. Push the SETUP button. Using the UP and DOWN arrow keys scroll to Engine Position Setup, then hit
YES.
4. The user will then be asked “How many engines are on the vessel?” Scroll UP or DOWN to select a
number between 1 and 5. Once the engine number selection is made, hit YES again.
5. Depending on the number of engines selected the following options will exist:
a. 1 is selected >> 'CENTER' (Fig. 1)
b. 2 is selected >> 'STBD' or 'PORT' (Fig. 2)
c. 3 is selected >> 'STBD' or 'CENTER' or 'PORT' (Fig. 3)
d. 4 is selected >> 'STBD' or 'STBD INBD' or 'PORT INBD' or 'PORT' (Fig. 4)
e. 5 is selected >> 'STBD' or 'STBD INBD' or 'CENTER' or 'PORT INBD' or 'PORT' (Fig. 5)
To scroll between engine location names use the UP and DOWN buttons. Then hit ‘YES’ once the
selection is made. Choose the correct location name based on the following engine location drawings.
6. Repeat this process (Steps 1 through 5) for each engine located on the vessel.
NOTE: Once the engine is configured, the engine installer must clearly label the DLC as to which engine it
supports.
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
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Trim Angle Configuration
The following describes how to properly setup an LED Trim Indicator. Trim angle configuration will be done in
three phases:
Phase 1) Set Drive Angle - Lower Input and Output
Phase 2) Set Drive Angle - Upper Input and Output
Phase 3) Set Running Drive Angle Input and Output
It is recommended that each phase of the drive angle configuration be done consecutively. After the initial
configuration, the user may adjust each phase individually.
Ensure that the engine’s ignition switch is in the OFF position. Locate the engine’s 6 pin OBD-M connector,
remove the connector’s protective cap, and plug in either the scan tool or the Diacom PC Software.
Once the tool is connected, the following step will need to be taken prior to pushing the SETUP button:
1. Turn the ignition ON, then select the correct ECU type (Ilmor – MV10 650 & MV10 725).
WARNING
On multi-drive installations, leave the tie bar disconnected during the drive angle configuration.
Failure to do so could result in an increased risk of personal injury or product / property damage.
Phase 1) Set Drive Angle – Lower Input and Output
1) Push the SETUP button and using the UP or DOWN buttons scroll to ‘Drive
Angle Input Setup’, and push YES
2) Three selections will be displayed when using the UP or DOWN buttons to
scroll to each selection. Scroll to select ‘Set Lower Input’. The raw
potentiometer reading in mV will be displayed on the tool.
3) Physically lower the drive to its minimum point, then push YES.
4) Either an ‘Accepted’ or ‘Error’ message will appear on the tool, to identify to
the user if the position is acceptable or not. If an ‘Error’ message appears it
may be due to the following: 1) the sensor is installed incorrectly, 2) the
wiring may be installed incorrectly, or 3) choose another mV selection. If the
‘Error’ message persists, please contact Ilmor H-P directly.
5) The tool will then proceed to ask ‘Do you want to set the lights on the Trim
Indicator?’ Push YES to continue, NO if you do not.
6) If YES is selected, use the UP and DOWN keys to adjust the light on the trim
indicator until the bottom most LED is lit, then push YES. The tool display will
show a raw mV value for the Drive Angle output.
7) The tool will then ask a verification question: ‘Are you at the bottom most
light?’ Push YES if the LED is at the bottom most light then continue to the
next phase, push NO if not and the tool will take you back to Step 6.
Fig. 1
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Phase 2) Set Drive Angle – Upper Input and Output
scroll to each selection. Scroll to select ‘Set Upper Input’. The raw
potentiometer reading in mV will be displayed on the tool.
3) Physically raise the drive to its maximum point, then push YES.
the user if the position is acceptable or not.
5) The tool will then proceed to ask ‘Do you want to set the lights on the Trim
Indicator?’ Push YES to continue, NO if you do not.
indicator until the top most LED is lit, then push YES. The tool display will
show a raw mV value for the Drive Angle output.
7) The tool will then ask a verification question: ‘Are you at the top most light?’
Push YES if the LED is at the top most light then continue to the next phase,
push NO if not and the tool will take you back to Step 6.
Fig. 2
Phase 3) Set Running Drive Angle Input and Output
scroll to each selection. Scroll to select ‘Set Running Drive Angle’. The
percentage reading in % will be displayed on the tool.
3) Physically adjust the drive to its intended running position, then push YES.
the user if the position is acceptable or not.
5) The tool will then proceed to ask ‘Do you want to set the blue LED?’ Push
YES to continue, NO if you do not.
indicator until the blue LED is lit, then push YES. The tool display will show a
mV value for the Drive Angle output.
7) The tool will then ask a verification question: ‘Is the blue LED on?’ Push YES
if the blue LED is lit, push NO if not and the tool will take you back to Step 6.
Drive angle configuration is now complete. If desired, the user also has the option of
readjusting the Trim Indicator lights at a later time.
During the configuration period is also a good time adjust the dimmer settings on the
Fig. 3
LED Trim Indicator if necessary. The dimmer is factory set to accommodate most
installations, but due to the variances in boat layout, adjustments may be necessary. On the rear of the LED
assembly are three blue potentiometers, one is marked with a D. The sensitivity of the dimmer can be adjusted
by turning this potentiometer clockwise for decreased sensitivity and counter-clockwise for increased sensitivity.
Turning the potentiometer to far either direction will result in greatly decreased sensitivity to light changes, but
will still allow the LED assembly to display drive position.
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Instrumentation
MV10 series engines can support coolant temperature, oil temperature, oil pressure, and sea-water pressure on
analog or otherwise compatible electrical gauges. A 0-5V output is provided to indicate drive angle and a
tachometer output is also available.
Many more parameters are available through the NMEA 2000 CAN network. This allows the owner to eliminate
the use of analog gauges if desired.
Water Temperature: Indicates the temperature of the engine coolant. The range of the water temperature
gauge which must be installed is 100 – 240F (38 - 115C)
Oil Temperature: Indicates the temperature of the engine oil. The range of the oil temperature gauge which
must be installed is 100 - 320F (38 - 160C)
Oil Pressure: Indicates the pressure of the engine oil. The range of oil pressure gauge which must be
installed is 0 to 80psi.
Tachometer: Indicates the engine speed. For the MV10, the tachometer rev range should be at least 0 to
7000 RPM. The tachometer must be compatible with 2.5 pulses per engine revolution (5V square wave).
Optional Instrumentation
Fuel Pressure: If a fuel pressure gauge is to be installed in the boat, a fuel pressure tap location can be found
on the right side of the fuel inlet filter. Replace the pipe plug with a suitable sender for the fuel pressure gauge.
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Sensor Layout
A
B
C
A – Oil Temp. Sender
B – Oil Pressure Sender
C – Water Temp. Sender (Gauge)
NOTE: All senders on the MV10 Gen. IV also serve as alarms.
Sensor Torques
Refer to the values given in - Engine Torque Specifications.
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Engine Monitoring Alarm System – MIL
The ILMOR High-Performance Marine engine alarm system will utilize a visual alarm to indicate an alarm
condition in which any of the monitored engine parameters falls out of the nominal operating range. In all
cases, the proper response to the alarm is to throttle back immediately and check the gauges to see which
system is out of range. The Malfunction Indicator Lamp (MIL) will remain lit until the issue has been corrected,
re-diagnosed, and the engine has gone through one full ignition cycle. If the fault continues to occur, the light
will remain on, until the failure condition has passed or the boat has been taken to a service center to be
correctly diagnosed and repaired.
A MIL will be indicated on the dash for each engine installed.
Alarm Activation Conditions:
Alarm
Threshold
Water Temperature
Oil Temperature
Oil Pressure
Over 200º F / 93C
Over 280º F / 137C
Less than 30psi / 200kPa
NOTE: The engine monitor alarm will display when the ignition is turned on without the engine running. The
alarm will shut off immediately when the engine is started and normal oil pressure exceeds 30psi. If the alarm
sounds for any other reason, contact your Ilmor authorized service center before re-starting the engine.
Refer to Appendix III – OBD-M Trouble Codes for a full list of components that may set the Malfunction
Indicator Lamp (MIL).
Water temperature
The alarm will appear if the engine coolant exceeds 212F / 100C. If this occurs, return the engine(s) to idle and
check the water temperature gauge and the sea water pressure gauge. If the sea water pressure is normal (>
5PSI at idle) the coolant temperature should start to return to normal. If the temperature continues to increase,
shut down the overheated engine immediately and take it to an authorized service center.
Oil pressure
The alarm will appear if the engine oil pressure falls below 30psi. If this occurs, throttle back and allow the
pressure to return above the 30psi level. If oil pressure remains below 20psi, return the engines to idle. If the
pressure continues to drop shut down the engine immediately and return to land. If at any time the oil pressure
drops to zero, shut down the engine immediately. Check the engine oil level in appropriate engine. If the oil
level is ok, take the engine to an authorized service center.
Oil temperature
The MIL light will illuminate if oil temperature exceeds 266F / 130C. Return the engines to idle and check the
oil temperature gauge. The oil temperature should start to return to normal. If the temperature continues to rise
shut down the overheated engine immediately and take it to an authorized service center immediately.
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Basic Engine Operation
Prior to Start Procedures
Oil Level (HOT)
(See “Engine Specifications” for correct viscosity)
The oil level indications on the dipstick are most accurate when the engine is sitting with the crankshaft
horizontal. Check the oil level with the engine not running and after the oil has had a few minutes to settle back
into the oil pan. The end of the dipstick shows a range of oil levels that are acceptable. If the oil cannot be seen
clearly within this range, add oil one quart at a time through the oil fill cap located on the front of the port side
valve cover until the desired level is achieved.
Be certain to check the engine oil level when the boat is in the level position. The best time to do this is when
the boat is on a trailer.
The oil dipstick is marked with the oil level that must be maintained. Failure to maintain the correct oil level will
ultimately lead to premature failure of the engine and the voiding of the warranty. Too low of an oil level could
cause the engine to lose oil pressure, which may lead to significant and permanent engine damage. Too high
an oil level can also cause damage to the engine due to excessive oil aeration.
MIN
Minimum
MAX
Maximum
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Starting the MV10
WARNING
Do not start the engine without a water supply to the seawater pump or damage to the seawater pump
impeller will occur. This could lead to the engine overheating and significant engine damage.
The following items should be checked on a daily basis:
1.
2.
3.
4.
5.
The fuel system for any signs of leaks.
Check sea water system for leaks.( pickups, sea strainer, shut off valves)
Engine coolant and engine oil levels.
Check power steering fluid level.
Exhaust system for leaks and loose fasteners.
If the exhaust headers are found to be leaking water, they could also be leaking water internally. It is very
important not to operate the engine. If water has leaked to the inside of the engine, severe engine damage
could result. Should a leak occur, the headers should be returned to Custom Marine Inc. (CMI) for repair.
Failure to follow these recommendations could lead to voiding of the manufacturer's warranty.
Always perform these safety checks prior to start.
1.
2.
3.
4.
Operate the bilge blowers for at least 60 seconds.
Check that the throttle is in the idle position.
Check that the gear selector is in the neutral position.
Shutoff valves at pick-ups and sea strainer are open.
Turn the key to the “ON” position. The instrument panel will power up. Turn the key to the start position until the
engine starts; release the key. Should the engine not start within the first 30 seconds, turn the ignition off and
wait two minutes for the starter to cool before attempting to restart the engine.
Once the engine has started, check immediately for proper oil pressure and that the voltmeter on the charging
system indicates greater than 13 volts.
Allow the engine to reach normal operating temperature (160F / 70C). Should the engine temperature rise
above 210F / 99C, shut off the engine immediately and determine the cause or contact an ILMOR HighPerformance Marine authorized dealer or service center.
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Stopping the Engine
When stopping the engine:
1. Bring the throttle levers to the idle position
2. Allow the engine to return to a stable low idle speed
3. Return the gear selector to the neutral position
4. Wait for all temperatures to stabilize for 30 seconds
5. Turn the ignition switch to the off position
Following extended periods of high speed operation, allow the engine to cool by maintaining a high idle speed
of 1200 RPM in neutral for several minutes before turning the ignition switch off.
Engine Break-in
All MV10 series engines are given a break-in and power test on a dynamometer prior to shipping.
The MV10 engine will continue to break-in over the first 25 hours of use. Light to moderate throttle is
recommended over the first two hours of operation. Proper break-in is essential to achieve maximum power,
minimal oil consumption and maximum longevity of the engine.
Special Precautions
NEVER EXCEED the maximum recommended engine speed as listed in “Engine Specifications”.
Never operate the engine at or near full throttle while in neutral. Never exceed two minutes of continuous full
throttle operation during the first five hours of running.
Do not attempt to break-in the engine by prolonged idling of the engine.
During the break in period, watch all gauges to confirm that the engines are operating normally. At any sign of
abnormal readings reduce your speed immediately and investigate.
Always, even after the break-in period, operate the engine(s) very cautiously until they have reached normal
operating temperature (170F / 77C coolant).
The break-in period is an excellent time to verify if the choice of propeller is correct. During full throttle running
with a normal load, the engine should reach the suggested full throttle RPM range as listed in “Engine
Specifications”. If the engine speed is lower than this during the full throttle running, consider changing to a
lower pitch, or a smaller diameter propeller. Conversely, if the engine speed is higher, either a larger diameter
or a higher pitch should be used.
During the break-in period, it is better to use a larger propeller and try to run at 5300 RPM. As the engines
break-in they will tend to achieve more RPM due to reduced internal friction.
During the break-in period, the engine oil level should be checked frequently and should be adjusted if needed.
It is normal for engines to consume some oil during initial running until the piston rings are fully seated.
It is preferable to perform the break-in over many stages, with a full cool down cycle after each outing. Check
the coolant level often to ensure proper level.
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WARNING
At the end of the 25 hour break-in period the boat must be brought to an authorized ILMOR HighPerformance Marine authorized marina or service center for the 25 hour service. Failure to do so will
result in voiding of the manufacturer's warranty.
Leakdown test
If there is any doubt about the performance of the engine, you should have a leakdown check performed.
During the leakdown check, leave the oil filler cap and the air filter off and position an assistant behind the
exhausts. If you do have a problem, you will hear the leak in one of these three areas. Leakdown levels of less
than 20% indicate a healthy engine.
Compression checks are not as useful, as they depend significantly on the state of the battery and if a small
leak does exist, it is not possible to find the source. A compression check can also lead to confusion in engines
such as the MV650 with variable cam timing, because the number produced depends greatly on where the cam
is positioned on shutoff.
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Fuel Requirements
The MV10 650 and 725 are high-performance engines and require premium fuel, with a minimum octane rating
of 91 (R+M)/2 or 95RON in Europe.
Use of lower octane fuels will cause spark knock (pinging). Continued heavy spark knock can cause severe
engine damage.
Warranty Information
It will be considered misuse of the engine(s) if they are damaged through the use of improper, low quality or low
octane gasoline. The warranty does not cover repairs to damage caused by misuse.
Gasoline containing Alcohol
Gasoline containing high levels of ethanol (>10%) or methanol alcohol is not recommended for use in the
MV10. This is primarily due to the fact that the alcohol in the fuel absorbs water. This water in the fuel can
cause corrosion and extensive damage in the fuel system. If the presence of alcohol in the gasoline is
unknown, frequent inspections of the fuel system are required.
WARNING
Gasoline is extremely explosive and highly flammable, and if ignited can cause serious
bodily damage or even death. Careful inspection of the entire fuel system for leaks and or
deterioration must be part of daily maintenance of the engines. This inspection is
mandatory after long periods of storage. The items to be checked include the fuel tanks,
fuel lines, fuel pump, regulator, the fuel rails, carbon canisters, and all fittings in the
system.
Replace any component which shows any signs of corrosion, leakage,
deterioration, swelling, hardening or softening.
Page 47
Owner's Manual
Revision - 5B
August 2009
Maintenance
Engine Oil
USE ONLY Mobil 1® Synthetic Motor Oil. The recommended oil is carefully formulated to provide excellent
protection to the engine under severe conditions, with no need for the use of supplemental additives. See
“Engine Specifications” for the correct oil viscosity for your model.
Warranty Information
It will be considered misuse of the engine(s) if they are damaged through the use of improper, low quality or
non specified oil. The warranty does not cover repairs to damage caused by misuse.
An oil change should be scheduled for every 25 hours of operation.
See “Maintenance - MV10 Maintenance Schedule” in the maintenance section.
The oil should also be changed if for any reason its temperature has exceeded 300º F.
Always change the oil filter each time the oil is changed, using only Ilmor approved filters as listed in
Appendix II - Service Parts.
Oil Capacity
The MV10 requires 8.5 quarts for fill after an oil and filter change.
Total fill (including cooler and lines) is 10 quarts.
Oil Removal
The MV10 engine has an engine oil drain hose
routed from the oil pan for ease of total oil sump
drainage. This hose has a yellow fitting on the
end. (See Fig.1)
Fig. 1
Page 48
Owner's Manual
Revision - 5B
August 2009
Engine Coolant
Each MV10 that is shipped from ILMOR High-Performance Marine is pre-filled with the proper amount of
coolant. This does not apply to engines shipped across international borders or overseas. Once the engine is
mounted in the boat, check to be sure that the heat exchanger is filled completely. Add a 50/50 coolant mixture
to the overflow tank until the tank is filled halfway. The sight tube allows a quick visual as to the coolant level.
Coolant Type
Only use coolant approved by ILMOR High-Performance Marine, as listed in “Engine Specifications” section.
A 50/50 solution of coolant and distilled water is suggested for optimal performance, to prevent corrosion within
the engine, and to preserve the water pump seals.
Capacity
Each engine requires two gallons of antifreeze and two gallons of distilled water, or 4 gallons tota,l to
completely fill the cooling system.
Power Steering Fluid
Only use power steering approved by ILMOR High-Performance Marine, as listed in “Engine Specifications”
section.
WARNING
Do not start the engine unless there is adequate power steering fluid in the power steering
pump reservoir, as severe damage to the pumping element could occur. Great care must be
taken when bleeding the power steering system to prevent running the pump dry. Should
the steering pump run for any length of time without fluid, loss of power steering and/or
permanent pump damage can result.
Page 49
Owner's Manual
Revision - 5B
August 2009
25 Hour Service
At the end of the 25 hour break-in period, MV10 engines must be serviced before the break in period can be
considered complete. The following list of maintenance items must be performed.
Change engine oil and filter.
Change fuel / water filter.
Check drive shaft and engine alignment.
Check coolant level and top off if needed.
Check power steering fluid level and top off if needed.
Check throttle and shift cables for proper end stop adjustment.
Check all hoses and lines for leaks or damage. Repair as necessary.
Check the complete exhaust system for damage or leaks. Check all hose clamps for tightness. Check that the
header bolts are tight.
NOTE: Do not over tighten header bolts; refer to the table in "Engine Torque Specifications".
Check the battery condition. Check that all battery connections are tight.
Check that the motor mounts and mounting bolts are tight.
Check that the starter, bell-housing bolts, and transmission bolts are tight.
Rebuild Schedule
Ilmor High-Performance Marine recommends that your MV10 series engine be rebuilt after 250 hours of use by
an authorized engine rebuild center.
Contact your local ILMOR High-Performance Marine service center to make arrangements.
Page 50
Owner's Manual
Revision - 5B
August 2009
Winterization
It is recommended to fog these engines if more than 8 weeks of storage is expected or if the boat is stored for
the winter (Do not stop fogging engines until stalling occurs).
A fuel stabilizer should be added at the end of the season before storage. Ilmor High-Performance Marine
recommends the use of STA-BIL brand Marine Formula fuel additives for this purpose.
The coolers should be drained of sea or raw
water by removing the front cover of the
oil/transmission cooler. The cover is held on by
one bolt, located in the center. This is a good
opportunity to inspect for and remove debris at
the front of the cooler. Once the cooler is
finished draining, reinstall the cover and tighten
the bolt. When installing the front cover, be sure
the rubber gasket is in position at the perimeter
of the cooler shell.
Remove this
cooler cover to
drain and clean
The headers can be drained by removing the blue plugs from
the water inlet manifolds located at the rear of each side of the
engine. Let the header and exhaust system drain, then reinstall
the plug.
Remove blue
plugs to drain
If the boat is to be stored in an area subject to freezing, the coolant should be checked for strength and
adjusted to be at least 50%, strong enough to withstand -40F and left in the engine.
If your boat has a sea strainer, drain the water to avoid freezing.
Page 51
Owner's Manual
Revision - 5B
August 2009
Ignition System
Firing Order: 1-10-9-4-3-6-5-8-7-2
Spark Plugs
See “Engine Specifications” for the proper spark plugs and gap for your engine.
Engine Torque Specifications
Component
Bolt
Alternator
Exhaust Headers
Power Steering Pump
Sea Pump - Block
Sea Pump - Body
Drive Plate - Bravo Style
Drive Plate - Huber Style
Spark Plugs
Motor Mounts - Block
M10 x 1.5
M8 x 1.25
M8 x 1.25
M8 x 1.25
1/4 - 20 UNC
3/8 - 16 UNC
3/8 - 16 UNC
M14 x 1.25
M10 x 1.5
M10 x 1.5
5/16 - 18 UNC
7/16 - 14 UNC
M6 x 1
Bellhousing
Transmission - Bellhousing
Lifting Eyes
Torque
N*m
47
24
27
27
12
47
47
19
47
54
34
54
11
in*lb
420
216
240
240
110
420
420
168
420
480
300
480
95
ft*lb
35
18
20
20
9
35
35
14
35
40
25
40
8
Threadlocker
Blue Loctite 243
CMD Anti-Seize Lubricant #3
Blue Loctite 243
Blue Loctite 243
Blue Loctite 243
Blue Loctite 243
Blue Loctite 243
CMD Anti-Seize Lubricant #3
Blue Loctite 243
Blue Loctite 243
Blue Loctite 243
Blue Loctite 243
WARNING
Page 52
Owner's Manual
Revision - 5B
August 2009
Maintenance Schedule
Item
Daily
Check oil level
Check coolant level
Check power steering fluid level
Check transmission oil level
Check sea strainer
Check fuel system for leaks
Check Fuel Water Seperator
Check exhaust system for water leaks
Cooling system condition of hoses and clamps
Serpentine belt for cracks and tension
Check
Every 25 Every 50
Annually
Hours
Hours
X
X
X
X
X
X
X
X
X
X
X
X
Starter motor - Check bolts are tight
X
X
Sea Pump - Inspect impeller
X
X
Air Filter / Flame Arrester Check for damage
Exhaust system condition of hoses and clamps
Check
X
Check
Motor Mounts Check
condition for cracks and fatigue
Motor Mounts Check mounting bolts are tight
Drive Plates - Check that bolts are tight
and that the plate is free of cracks
Battery Check electrolyte level and case
Battery cables and connections Check for corrosion
Battery cables and connections Check for tight
Electrical system for damaged wiring
Fuse block and relays Check for corrosion
Check
Hoses and lines for swelling and deterioration
Check
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Throttle Cable - Inspect for damage
X
X
Shift Cable - Inspect for damage
X
X
Page 53
Owner's Manual
Revision - 5B
August 2009
Replacement Intervals
Item
Serpentine Belt
Sea Pump Impeller
High Pressure Fuel Filter
Fuel Water Separator
Oil Filter
Spark Plugs
Air Filter
Rubber hoses
Interval
Annually
Every 25 hours or after winterization
Every 50 hours or after winterization
Every 25 Hours*
Every 25 Hours
Every 2 years or after winterization
Every 100 Hours
Every 2 Years**
* Pending inspection of component. The fuel water separator should be inspected regularly and changed when
water begins to accumulate. Close attention should be paid after filling the fuel tanks and more frequent
replacement may be required.
** Inspect for cracking, swelling, or deterioration regularly and replace when necessary.
Page 54
Owner's Manual
Revision - 5B
August 2009
Engine Specifications
Required Fuel Octane
91 (R + M)/2 Minimum
Engine Coolant
5 Yr/100,000 mile formula antifreeze (50/50 mix)
Engine Oil
0W40 Mobil 1® Synthetic
Power Steering Fluid
Mobil 1® ATF
Recommended Engine Speed
MV650
-
95RON
5500-6100 RPM (6300 RPM limit)
MV 725 5800-6300 RPM (6500 RPM limit)
Spark Plugs
MVP4560
Normal Oil Pressure
50 – 75 psi with warm oil
MV650 50psig at IDLE
58 psig at WOT
MV725 68psig at IDLE
72 psig at WOT
5 to 10psig (0.3 to 0.7 bar ) at IDLE
Normal Fuel Pressure
Normal seawater pressure
30 to 50psig (2 to 3.4 bar ) at WOT
Normal Coolant Temperature
155 – 180º F 68C - 82C
Normal Oil Temperature
150 – 230º F 66C - 110C
Page 55
Owner's Manual
Revision - 5B
August 2009
Appendix I - MV10 Diagrams
MV10 - DRIVE BELT ROUTING
Page 56
Owner's Manual
Revision - 5B
August 2009
MV10 - Front View
Page 57
Owner's Manual
Revision - 5B
August 2009
MV10 - Port Side
Page 58
Owner's Manual
Revision - 5B
August 2009
MV10 - Starboard Side
Page 59
Owner's Manual
Revision - 5B
August 2009
Appendix II - MV10 Service Parts Listing
Component
ALTERNATOR, SAE J1171
Serpentine BELT
BUSHING, Mercury Style Bellhousing
CAP, heat exchanger
CLAMP, exhaust, downturned headers
CLAMP, exhaust, straightback headers
CLAMP, T-bolt 3.5" (Oil Cooler/Heat Ex.)
CLAMP, T-bolt 4.5" (Exhaust)
COOLER, Oil and Trans
COOLER, Power Steering
COOLER, Fuel
COOLER, Engine Coolant
DECAL, Coast Guard App.
DECAL, CARB 3 - Star ( 5 x 6")
HANG TAG, CARB
DRIVE COUPLER, Mercury Style
DRIVE COUPLER, Transmission Style
FILTER, Air
FILTER, Oil
FILTER, Fuel - High Pressure
FILTER, Fuel / Water Separator
FITTING KIT, Power Steering
GASKET, Exhaust (each)
IMPELLER, Seapump
PLUMBING KIT, Trans
PLUMBING KIT, Fuel
PULLEYS, Billet w/ power steering
PUMP, Fuel
REGULATOR, Fuel
SENSOR, Oil Press, Water Press
SENSOR, Oil Temperature
SENSOR, Water Temperature
SENSOR, Manifold Air Pressure (MAP)
SENSOR, Manifold Air Temp. (MAT)
SPARK PLUG
Ilmor Part #
PE00847
MVP 0165
MVP 0037
MVP 0003
MVP 0092
MVP 0092
MVP 0204
MVP 0174
PE00907
PE01059
PE01055
PE00814
MVP 0085
MVP0490
MVP0499
MVP 0036
MVP 0293
PE00808
MVP 0285
MVP 0421
MVP 0162
MVP0135
MVP 4610
MVP0102 (black)
MVP 0401
MVP0427
MVP 0423
MVP 0420
MV650 MVP0438
MV725 MVP0430
MVP 4825
MVP 4830
MVP 4830
MVP 4835
MVP 0081
MVP4560
Page 60
Owner's Manual
Revision - 5B
August 2009
Appendix III – OBD-M Trouble Codes
NOTE: All fault codes listed below will display a Malfunction Indicator Lamp (MIL) on the dash (Fig. 1l). The
following fault codes will be stored and will only display a MIL under the following conditions:
*Fault
Indication of Fault
Battery Voltage High
Battery Voltage Low
Engine Coolant Over Temperature
Oil Pressure too Low
Engine Oil Over Temperature
Drive Oil Pressure too Low
Transmission Oil Over Temperature
No MIL indication, fault code stored
No MIL indication, fault code stored
MIL only when temperature exceeds threshold, fault code stored
MIL only when pressure falls below threshold, fault code stored
MIL only when pressure falls below threshold, fault code stored
A MIL will be indicated on the dash, one for each engine installed.
NOTE: Once the MIL is indicated on the dash for any of the five faults specified above, it will remain lit until the
issue has been corrected, re-diagnosed, and the engine has gone through one full ignition cycle. If the fault
continues to occur, the light will remain on, until the failure condition has passed, or the boat has been taken to
a service center to be correctly diagnosed and repaired. For all other faults, the MIL will turn off after three
good warm-up cycles, only if the fault does not re-occur. If the fault continues to fail, the MIL light will remain on
as a reminder that service is required.
WARNING
Specific fault codes will trigger a MIL indication followed by a "forced idle", in which the engine
will operate at approximately 2000 rpm or 25% of its duty cycle. These fault codes are indicated by
a (**) demarcation. Attention should be paid to any MIL indication as this can be especially
hazardous in multiple engine configurations.
The following table identifies the component that is being tested. The Suspect Parameter Number (SPN) is the
fault code which is stored in the computer’s memory. The Failure Mode Indicator (FMI) number provides the
technician with more detail as to why the fault occurred. Together the SPN and FMI make up a part of the
Diagnostic Trouble Code (DTC).
Page 61
Owner's Manual
Revision - 5B
August 2009
Component
SPN
FMI
Display Name for SPN/FMI Combination
Pedal Position Sensors (1 & 2)
28
2
Pedal Position Sensor 1/2 Correlation
Throttle Position Sensors (3 & 4)
2977
2
Throttle Position Sensor 3/4 Correlation
51**
51**
51**
2976
2976**
100
100
100
100
2
7
14
2
10
2
3
4
1
Engine Throttle Position 1
Throttle 1 - Unable to Close
Throttle 1 - Unable to Open
Throttle Position Sensor 1/2 Correlation
Throttle Position Sensors
Oil Pressure Sensor
Oil Pressure Sensor - Voltage High
Oil Pressure Sensor - Voltage Low
Oil Pressure too Low*
106
106
106
110
110
2
3
4
0
1
110
3
110
4
167**
167
167**
167
168
168
172
2
3
4
7
3
4
2
172
3
172
4
175
175
175
175
0
2
3
4
177
0
177
3
177
4
Manifold Absolute Pressure Sensor
Manifold Absolute Pressure Sensor High
Manifold Absolute Pressure Sensor Low
Engine Coolant Over Temperature*
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor - Circuit
High
Engine Coolant Temperature Sensor - Circuit
Low
Voltage Sense
Voltage Sense High
Voltage Sense Low
Voltage Sense Mid-Range
Battery Voltage High*
Battery Voltage Low*
Intake Air Temperature Sensor
Intake Air Temperature Sensor - Out of range
high
Intake Air Temperature Sensor - Out of range
low
Engine Oil Over Temperature*
Oil Temperature Sensor
Oil Temperature Sensor Voltage High
Oil Temperature Sensor Voltage Low
Transmission Oil Temperature - Over
Temperature*
Transmission Oil Temperature Sensor Voltage
High
Transmission Oil Temperature Sensor Voltage
Low
723
7
Throttle 1
Throttle Position Sensors
Oil Pressure Sensor
Manifold Absolute Pressure Sensor
Engine Coolant Temperature Sensor
Voltage Sense
Battery Voltage
Intake Air Temperature Sensor
Engine Oil Temperature Sensor
Transmission Oil Temperature
Engine Speed Sensor
Cam-Crank out-of-tolerance (based off of engine
speed sensor)
Page 62
Owner's Manual
Revision - 5B
August 2009
Component
SPN
FMI
Display Name for SPN/FMI Combination
Knock Sensor 2
731
2
Knock Sensor 2
Knock Sensor 1
1352
2
Knock Sensor 1
Engine Coolant System Thermostat
1659
7
Engine Coolant System Thermostat
2972
2972
2973
2973
3
4
3
4
Throttle Position Sensor 1 - Voltage High
Throttle Position Sensor 1 - Voltage Low
2974
2974
2975
2975
91
91
29
29
3306
3306
3306
3464**
3
4
3
4
3
4
3
4
7
6
5
2
3464**
8
3464**
3465**
12
2
3465**
8
3465**
3509**
3509**
3510**
3510**
3511**
3511**
3673**
3673**
3673
520192
520192
520192
12
3
4
3
4
3
4
2
7
14
3
4
1
Pedal Position Sensor 1 - Voltage High
Pedal Position Sensor 1 - Voltage Low
Pedal Position Sensor 2 - Voltage High
Pedal Position Sensor 2 - Voltage Low
VVT - Exhaust Cam Position Control Solenoid
VVT - Exhaust Valve Solenoid High
VVT - Exhaust Valve Solenoid Low
Electronic Throttle Control System 1
Electronic Throttle Control System 1 - Abnormal
Operation
Electronic Throttle Control System 1 - Pic fault
Electronic Throttle Control System 2
Electronic Throttle Control System 2 - Abnormal
Operation
Electronic Throttle Control System 2 - Pic fault
5VRef_A Circuit High
5VRef_A Circuit Low
5VRef_B Circuit High
5VRef_B Circuit Low
5VRef_C Circuit High
5VRef_C Circuit Low
Engine Throttle Position 2
Throttle 2 - Unable to Close
Throttle 2 - Unable to Open
Drive - Oil Pressure Sensor - Voltage High
Drive - Oil Pressure Sensor - Voltage Low
Drive - Oil Pressure too Low*
Throttle Position Sensor 1
Pedal Position Sensor 1
Pedal Position Sensor 2
Variable Valve Timing (VVT)
ETC System 1
ETC System 2
5VRef_A
5VRef_B
5VRef_C
Throttle 2
Drive – Oil Pressure Sensor
Page 63
Owner's Manual
Revision - 5B
August 2009
Appendix IV - Wiring Schematics
Power and Ground Wiring
Page 64
Owner's Manual
Revision - 5B
August 2009
NMEA 2000 / CAN Connection - Boat - MV10, Dual Engine Layout
Page 65
Owner's Manual
Revision - 5B
August 2009
Engine - Dash Connections
Page 66
Owner's Manual
Revision - 5B
August 2009
Engine - Helm Cable Terminations Diagram
Page 67
Owner's Manual
Revision - 5B
August 2009
Engine - Helm Cable Terminations Photo
Engine to Helm Gauges - Cable #1
14 way Connector, engine sensor outputs - connects to Cable #2
Page 68
Owner's Manual
Revision - 5B
August 2009
INDY® - Engine Hook-up
Page 69
Owner's Manual
Revision - 5B
August 2009
NOTES
Page 70
Owner's Manual
Revision - 5B
August 2009
Maintenance Log
Date
Service Performed
Engine Hours
Page 71

Owner`s Manual MV10 Gen. IV Series Engines

Transcription

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