ILMOR MV-10 Owner's Manual & Installation Manual

Brand: ILMOR

Model: MV-10

Type: Owner's Manual & Installation Manual

Owner’s Manual & Installation Guide

Revision 6e

ILMOR Marine Engines LLC

43939 Plymouth Oaks Blvd. • Plymouth, MI. 48170 • www.ILMOR.com • (734) 456-3600

Owner’s Manual &

Installation Instructions

Revision 6e

Page 2

INDEX Page

Welcome............................................................................................................................................ 3

Safety Information.............................................................................................................................. 4

Replacement Parts.............................................................................................................................. 4

Hoist Points for engines equipped with lifting lugs................................................................................. 5

Hoist Points for engines....................................................................................................................... 6

Mounting the Engine........................................................................................................................... 7

Leveling Engine .................................................................................................................................. 10

Exhaust System.................................................................................................................................. 11

Fuel Injection System – All Models....................................................................................................... 13

Fuel Injection System – 550 and older 625 models ............................................................................... 14

Fuel Injection System – 570, newer 625, and 7-10 models.................................................................... 19

Throttle Cable Connection ................................................................................................................... 20

Engine Cooling System........................................................................................................................ 21

Power Steering System ....................................................................................................................... 25

Electrical System................................................................................................................................. 26

Electrical System – Fuse Box ............................................................................................................... 27

Electrical System - Power Distribution and fuse box layout .................................................................... 27

Electrical System – Boat/Engine Interface Wiring.................................................................................. 28

Electrical System - Engine Wiring......................................................................................................... 31

Electrical System - ECM Pin-Out........................................................................................................... 31

Electrical System – Instrumentation..................................................................................................... 34

Electrical System - Sensor Layout ........................................................................................................ 35

Engine Monitoring Alarm System.......................................................................................................... 36

Prior to Start Procedures ..................................................................................................................... 37

Starting the MV10...............................................................................................................................38

Engine Break-in .................................................................................................................................. 39

Stopping the Engine............................................................................................................................ 40

Fuel Requirements.............................................................................................................................. 41

Maintenance – Oil Change................................................................................................................... 42

Maintenance - Engine Coolant ............................................................................................................. 43

Maintenance - Power Steering Fluid ..................................................................................................... 43

Maintenance - 25 Hour Service............................................................................................................ 44

Maintenance - Winterization ................................................................................................................ 45

Maintenance – Ignition System............................................................................................................ 46

Engine Fastener Torque Specifications ................................................................................................. 47

Maintenance - MV10 Maintenance Schedule ......................................................................................... 49

Engine Specifications........................................................................................................................... 50

MV10 Service Parts Listing................................................................................................................... 51

Owner’s Manual &

Installation Instructions

Revision 6e

Page 3

Welcome

ILMOR Marine Engines would like to thank you for selecting the Ilmor MV10

for your boating needs.

The MV10 engine by ILMOR Marine represents a new opportunity for the boating world to

enjoy a great performing, totally new powerplant. Based on a lightweight, high-output V10,

the concept of this engine package is to reliably deliver high-performance 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, excellent drivability and overall user

friendly character.

PLEASE READ THIS MANUAL PRIOR TO INSTALLING OR OPERATING THE

ENGINE(S).

Owner’s Manual &

Installation Instructions

Revision 6e

Page 4

Safety Information

Throughout this manual there are several safety warnings and information to point out the

hazards of performing maintenance and service procedures in a careless or incorrect

manner. The warnings alone cannot cover every possible danger involved in servicing the

MV10. Please pay strict attention to all warnings while performing any service.

It is the owner / operators responsibility to perform all safety checks to the engines before

operating the boat. All maintenance and lubrication schedules, when properly adhered to

will ensure long life and great performance of the MV10 engine. When service and

maintenance are required please return the boat to an ILMOR Marine dealer or authorized

ILMOR service center.

Replacement Parts

A list of ILMOR approved MV10 parts are in the appendix of this manual.

WARNING

Use only genuine ILMOR Marine Engines 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.

Parts required for service or repairs are available from:

ILMOR Marine Engines LLC

43939 Plymouth Oaks Blvd.

Plymouth, MI 48170

Phone: (734) 456-3600

Fax: (734) 456-3699

Owner’s Manual &

Installation Instructions

Revision 6e

Page 5

Hoist Points for engines equipped with lifting lugs.

WARNING

Retaining bolt must be torqued to 50 ft/lb. A lifting strap or chain must be used to lift the

MV10 engine. The chain must have a load bearing capacity of at least 1,000lb. All hooks,

cranes and rigging used to lift the engine must also have at least 1,000lb load capacity.

The MV10 should be lifted by a chain loop or strap slung between two lift points on the

engine.

Front Lift Point - The front lift point of the

MV10 is best provided by lifting eye PN:

PT00755C. This bracket attaches to the port

head with a 7/16 UNC x 5” bolt (50 ft/lb

torque) and provides an eyelet to attach a

lifting strap. This bracket greatly reduces the

chance of damage to the engine and

accessories. See Fig. 1.

Fig. 1

Rear Lift Point - The rear lifting point is the

large hole located in the accessory mounting

plate. The lifting chain must be looped

through this hole and securely fastened with a

bolt. A spreader bar should be used to

ensure that the chain does not tug sideways

into the valve covers. Great care must be

taken as the engine is being lifted or damage

to the engine may occur. Ensure the chain

loops freely between the pick up points and is

not fowling the headers or any other part of

the engine or wiring. See Fig. 2

Fig. 2

Owner’s Manual &

Installation Instructions

Revision 6e

Page 6

Hoist Points for engines.

1. Insert Lifting Hook (part number:

pt00839a) by feeding insertion cable

between the second and third sets of

intake port runners (from the front of

the engine) and out through the top of

the intake manifold as shown. This

location is the balance point of the

engine.

2. Pull the insertion cable to position

the lifting hook into position (hook

wedges symmetrically in the intake

manifold).

3. Lift by attaching the hoist to lifting

hook pt00839a (not the insertion

cable). A lifting strap or chain must

be used to lift the MV10 engine. The

chain must have a load bearing

capacity of at least 1,000lb. All

hooks, cranes and rigging used to lift

the engine must also have at least

1,000lb load capacity.

Owner’s Manual &

Installation Instructions

Revision 6e

Page 7

Mounting the Engine

The MV10 is supplied with motor mounts which allows installation into typical V-hulls and

catamarans with single, dual or triple engine configurations.

Engine Mounting: Plate Options, views from stern to bow:

Often referred to as an “offshore” plate, this style incorporates mounts at the engine block

joined with a plate passing below the engine.

Standard Front Plate (PE00575)

Stringer mounting hole spacing: 20.2” centered.

These mounts fit the majority of v-hulls and catamarans on

the market with a two stringer set-up, can be used for single

or multiple engine applications.

Standard Rear Plate (PE00452)

Stringer mounting hole spacing: 20.2” centered.

Center Front Plate (PE00671)

Stringer mounting hole spacing: 31” centered.

These mounts are 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 plate is reinforced to control front to rear

engine motion. These mounts are typically used for

single engine boats utilizing a driveshaft or unsupported

transmission and triple engine boats where the center engine is mounted forward and/or

utilizing a driveshaft or unsupported transmission.

Owner’s Manual &

Installation Instructions

Revision 6e

Page 8

Mounting the Engine cont’d

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

mounted slightly ahead

of the other (staggered).

A drive-extension kit must be

used with the forward engine,

typically referred to a as a “driveline” setup.

Note: driveline engine packages are supplied without headers.

Staggered Rear (PE00566)

Stringer mounting hole spacing: From crankshaft, 6.9” (low side) & 14.9” (high side).

This plate 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).

Owner’s Manual &

Installation Instructions

Revision 6e

Page 9

Mounting the Engine cont’d

Engine Mounting: Motor Mount Options, views from stern to bow:

Foot Mounts, 2 required (PE00524)

Stringer mounting hole spacing: 22.5” centered.

Common mounting system through the use of individual mounts

on each side of the engine with no plate connecting them.

These mounts fit a ¾” diameter vertical stud.

Again fits the majority of boat/engine combinations with two stringers.

2 required per engine.

Engine Mounting: Bell Housing Options, views from stern to bow:

Bravo style (PE00389)

This bell housing features two rear mounting bosses designed to

pick up the standard inner transom plate used with the “Bravo”

style drives.

Transmission style (PE00263)

This bell housing is intended for Series 72 gearboxes used with

driveshaft outdrive configurations. The rear of the engine must

be supported by either a engine plate or transmission mounted

support.

Owner’s Manual &

Installation Instructions

Revision 6e

Page 10

Leveling Engine

When leveling the engine, good reference surfaces are the fuel rail and the top edges of

the valve covers, as these surfaces run parallel to the crankshaft centerline.

Owner’s Manual &

Installation Instructions

Revision 6e

Page 11

Exhaust System

There are currently two styles of headers available for the MV10, straight back and down-

turned, with several configurations of the down-turned offered.

Fig. 3 Down-Turned (MVP 0117) Fig. 4 Straight Back (MVP 0118)

Down-turned headers are the standard headers offered with the MV10 (Fig. 3). Optional

tail pipes are available which have been designed to exit through transoms drilled for

traditional Bravo applications. Straight back headers are available for special use

applications (Fig. 4).

Down-turned headers are also available in “straight up” (Fig. 5) and “tipped-in” (Fig. 6)

configurations. This aids in gaining necessary header to boat clearance. Some dual-engine

configurations may require one straight up and one tipped-in on each engine to gain

additional clearance.

Fig. 5 Straight-up (MVP 0117) Fig. 6 Tipped-in (MVP 0141)

Owner’s Manual &

Installation Instructions

Revision 6e

Page 12

Exhaust System cont’d

Header 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 bolts are misaligned or over-tightened.

Begin by loosely installing all the hardware and then draw the header in evenly by going

over all bolts several times. Final torque should be 25 ft lb.

Tailpipes for a standard Bravo set-up are available directly from ILMOR Marine Engines

under part number MVP 0152. Custom tailpipes are to be obtained directly from CMI.

Care must be taken to provide adequate clearance between the tailpipes and the transom.

If the tailpipes do 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 CMI 4-1/2” sweeper flex

flare clamps available from CMI, ILMOR Marine Engines or any ILMOR authorized service

center.

MV10 tailpipe clamps are available for purchase from any of the following:

• ILMOR Marine P/N MVP 0169 (Clamp kit includes clamp, tailpipe

jumper, hose clamps, gasket, t-bolt & nut)

• CMI P/N 36260 (Clamp only)

• RG RAY P/N 500048-1 (Clamp only)

Owner’s Manual &

Installation Instructions

Revision 6e

Page 13

Fuel Injection System – All Models

WARNING

All fuel system plumbing must be in accordance with US Coast Guard (USCG) regulations

using hose which meets or exceeds SAE Standard J1527DEC85.

All hose used for fuel delivery must meet or exceed specification in USCG regulations

sec.183.540 for recreational boating.

WARNING

The fuel pump supplies fuel to the engine a regulated pressure (see MV10 Service Parts

Listing). 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. All lines and fittings used in

the fuel system must meet or exceed the USCG requirements for fuel systems.

Each MV10 is supplied with a complete fuel delivery system installed. Components

include: fuel pump, water separator fuel filter and fuel pressure regulator with high

pressure fuel filter. A ½” 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 (on return fuel systems) must be run back to

the fuel tank. Warranty coverage may be denied if fuel supply line smaller than ½” 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 Marine

Engines by calling (734) 456-3600 or e-mail: sales&[email protected]

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, including the use of non-ILMOR specified service parts

unless such modification or use of parts is requested and approved by ILMOR in writing.

Please call ILMOR Marines Engines before altering the fuel delivery system in any

way.

Owner’s Manual &

Installation Instructions

Revision 6e

Page 14

Fuel Injection System – All Models cont’d

FUEL RAILS

The fuel rails are fed from the regulator output using a quick-release fitting and a

combination of hard line and USCG approved fuel line. The fuel rails are connected at the

rear of the engine through the use of the OEM, crossover pipe. See fuel system diagram

on page 11 for further fuel system detail.

FUEL RAIL COVERS

On the underside of each cover there are three rubber grommets that, when the cover is

installed, snap over three ball-nut mounts on the engine (see figure 8). Some models are

not equipped with carbon fiber fuel rail covers.

Rail Cover Mounts - To remove covers, carefully feel where the mounts are located and

slowly pull straightaway from the engine. Installation is best accomplished by applying

soapy water to the grommets, lining up the grommets & mounts then applying a light but

steady pressure directly to the grommet/mount location.

Fig. 8

Owner’s Manual &

Installation Instructions

Revision 6e

Page 15

Fuel Injection System – 550 and older 625 models

(without return to tank fuel)

FUEL SYSTEM DIAGRAM

RETURN LINE

58psi REGULATED PRESSURE

A. MVP0115 TANDEM COOLER OIL/FUEL

B. MVP0136 WATER FUEL SEPARATOR

C. MVP0025 FUEL PUMP

D. MVP0111 FUEL FILTER/REGULATOR

E. FUEL TANK IN BOAT

F. MV10 FUEL RAIL

Fig. 7

Owner’s Manual &

Installation Instructions

Revision 6e

Page 16

Fuel Injection System - 550 and older 625 models cont’d

(without return to tank fuel)

FUEL FILTER / WATER SEPARATOR – Fig. 9

Fuel supply from the tank must be run directly to the fuel filter / water separator. The

separator is located near the rear of the engine on the port side. All fuel supply lines on

the suction side of the fuel pump must be a minimum of ½” inside diameter or larger where

possible. The inlet/outlet plugs can be fitted as needed to provide right-hand or left-hand

orientation following the flow direction arrows cast into the filter base.

FUEL PUMP – Fig. 10

The fuel supply plumbing from the filter to the fuel pump is a combination of hard, formed

steel and soft rubber lines. The fuel pump is mounted on the port side of the engine just

above the oil pan rail. A soft bracket and two bolts hold the pump to the block. The MV10

utilizes a “Smart Start” strategy for safety and is controlled via the electronic control unit

(ECU). When turning the ignition key to ON or START, the pump will run for

approximately four seconds to prime the fuel system and then stand-by until the engine

starts. The fuel pump will turn on and remain on while the engine is running. When the

engine stops running the ECU will automatically shut the fuel pump off.

FUEL PRESSURE REGULATOR – Fig. 11

High pressure fuel from the cooler is plumbed to the pressure regulator. There are three

ports on the regulator. The smallest of which is a 1/8” return that is plumbed back to the

separator. Excess fuel recirculates back to the filter / water separator then flows through

the cooler in an effort to minimize vapor lock. See fuel regulator figure 11 on page 14 for

further detail. A complete fuel system schematic is available on page 11 as figure 7.

FUEL COOLER – Fig. 12 & 13

Once the pressurized fuel has left the pump, the fuel supply is cooled through the use of a

heat exchanger. The cooler is located beneath the engine, ahead of the oil pan sump. This

cooler is dual-purpose, cooling both the fuel and engine oil with cool seawater. The fuel

enters on the port side, flows through the cooler and exists on the starboard side of the

engine.

Owner’s Manual &

Installation Instructions

Revision 6e

Fuel Injection System - 550 and older 625 models cont’d

(without return to tank fuel)

FUEL FILTER/ WATER SEPARATOR ADAPTER

A – Fuel inlet from tank. Use right-hand or left-

hand as necessary, following arrows cast into filter

base.

B – Fuel outlet to fuel pump. Again use right-hand

or left-hand as necessary, following arrows marked

on adapter.

Page 17

Fig. 9

FUEL PUMP

A – Positive connection terminal. Connect

green/white stripe wire with 3mm ring terminal.

B – Negative (ground) connection terminal.

Connect tan wire with 4mm ring terminal.

*Posts are labeled with a (+) and (-)*

Fig. 10

FUEL PRESSURE REGULATOR / HIGH PRESSURE FILTER

A – Excess fuel return to

water/fuel separator.

B – Fuel inlet from cooler.

C – Outlet to fuel rails

(quick-release fitting).

Fig. 11

Owner’s Manual &

Installation Instructions

Revision 6e

Page 18

Fuel Injection System - 550, older 625, and older 7-10 models

FUEL/OIL COOLER

Starboard (Right) Side:

F G

A D

B Fig. 12

Port (Left) Side:

I J H

Right Side Left Side

A – Seawater Outlet H – Seawater Inlet

B – Plug (remove for fuel pressure gauge) I – Oil Pressure Sender

C – Fuel outlet to regulator J – Oil Temperature Sender

D – Oil engine in K – Fuel Inlet

E – Oil pressure alarm sender L – Zinc Plug

F – Oil engine out

G – Zinc Plug 3/8” male NPT (remove for seawater pressure gauge)

Fig. 13

Owner’s Manual &

Installation Instructions

Revision 6e

Fuel Injection System – 570, newer 625,

and 7-10 models

(with return to tank fuel)

Page 19

Owner’s Manual &

Installation Instructions

Revision 6e

Page 20

Throttle Cable Connection

Throttle Stop and Cable Mount - The

MV10 is provided with mountings suitable

for use with industry standard Morse

cables.

The throttle is spring loaded and is closed

(or at idle) when resting on the throttle

lever stop screw. The cable should be

fitted to allow full-throttle control

movement, from the idle stop (throttle

closed) to the full-throttle stop. Any

fasteners used should be self retaining

(Nylock, K-nuts or interference self locking

nuts) Fig. 14

To ensure proper throttle operation, operate the throttle system prior to attaching the cable

to the engine. The movement must be smooth and free with no binding.

The full-throttle stop and cable adjustment must be set such that full-throttle is full travel of

the throttle handle at the helm. Excess movement can place strain on the cable and other

components, which could result in component failure. The idle stop is provided at the

engine by a hard stop screw which must never be adjusted.

IMPORTANT

When fully warm, the engine will idle at 800 rpm and is electronically controlled via the

ECU. Adjustment of the throttle butterflies will not change the idle speed and could cause

significant engine damage. It is important that the throttle quadrant is resting on the closed

or idle stop when the throttle butterfly is on the idle stop.

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ILMOR MV-10 Owner's Manual & Installation Manual

Brand: ILMOR

Model: MV-10

Type: Owner's Manual & Installation Manual

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ILMOR MV-10 Owner's Manual & Installation Manual

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