Marinediesel 6 User manual

TABLE OF CONTENTS
1. GENERAL INFORMATION
Application …………………………………………………………………..
Identification ………………………………………………………………...
Break in procedure ...………………………………………………………...
Starting procedure …………………………………………………………...
Winter storage………………………………………………………………..
Procedures after winter storage ……………………………………………...
Periodic maintenance ………………………………………………………..
Technical maintenance specifications ……………………………………….
Warranty ……………………………………………………………………..
Dealer & Service directory …………………………………………………..
Exhaust manifolds …...………………………………………………………
Supercharger and intercooler system ………………………………………..
Impeller pump ……………………………………………………………….
Raw water and fuel connections …………………………………………….
Oil filter relocator …………..………………………………………………..
1
2
2
2
3
4
5
5
5
6
6
7
11
11
12
2. ENGINE MECHANICAL
Specifications ………………………………………………………………..
Diagnostic … ………………………………………………………………...
Cylinder block and components ……………………………..………………
Front cover, oilpan and components ………………………..……………….
Fuel system components …..………………………………………………...
Serpentine belt system …..…………………………………………………...
Valve cover replacement …………...………………………………………..
Rocker arm replacement ………...…………………………………………...
Valve lifter replacement ……………………………………………………..
Crankshaft Balancer replacement ….. ……………………………………….
Engine front cover replacement ……………………………………………..
13
18
29
31
33
34
41
45
53
58
61
Timing chain replacement …………………………………………………..
Camshaft replacement .……………………………………………………...
Crankshaft rear oil seal replacement ..………………………………………
Oilfilter adapter replacement .……………………………………………….
Oil pan replacement ………………………………………………………...
Oil pump replacement ….…………………………………………………...
Fuel injection pump removal ………………………………………………..
Timing chain wear check …….……………………………………………...
Engine disassembly and assembly …………………………………………..
Engine component description ………………………………...…………….
67
70
74
77
78
81
84
87
90
145

3. DIAGNOSTIC INFORMATION
Diagnostic Strategy 150
4. INSTALLATION
Important installation notes ..………………………………………………..
Engine ……………………………………………………………………….
Air Intake System ……………………………………………………………
Fuel System ..………………………………………………………………...
Exhaust System …………………………………………………………….
Cooling System ……………………………………………………………...
Electrical System ..…………………………………………………………...
Predelivery …………………...……………………………………………...
Predelivery inspection checklist ……………………………………………..
169
171
180
183
189
196
203
210
218
5. SERVICE INSTRUCTIONS
Service information 223

1
APPLICATION
In 1998, Marinediesel introduced it’s 6,5L V8 supercharged, intercooled marine engine
(see drawing below) for light duty commercial and pleasure craft applications.
The base engine is manufactured at the General Engine Products ( a division of AM
General) 92,000 square foot production facility, located in Franklin, Ohio. The Optimizer
6500 base engine is Euro III and QS 9000 certified. The engine is marinized and marketed
by Marinediesel AB, headquarters located in Engelholm Sweden and PPT located in
Stillwater Oklahoma.

2
IDENTIFICATION
The Marinediesel engine has a stainless steel serial number tag located on the rear
starboard side of the engine block. This serial number tag will reflect the engines six digit
serial number starting with MD-######.
BREAK IN PROCEDURE
All Marinediesel engines have a break-in period during the first 20 hours of operation.
During this break-in period the engine should not be run at more than 75% throttle for
more than very short time-periods. Also never have the engine run at excessive loads
during the break-in, apart from this the engine can be used as normal.
Starting procedure
Before starting the engine always check the oil and coolant level. Also inspect that no
leaks on oil-, fuel- or cooling systems are evident.
1. Make sure gear is in neutral and that throttle is in idling position.
2. Turn ignition key to the ON position and wait for glow light to stop. This allows the
automatic glow system to glow it’s first sequence.
Serial
Number
Tag
######

3
Warning: DO NOT USE STARTING AIDS SUCH AS STARTING GAS; ETHER OR
OTHER. (this will void any warranty.)
3. Turn the ignition key to the CRANK position to start the engine. If the engine doesn’t
start in 15 seconds, wait for 30 seconds and go back to step 2.
As soon as the engine starts, let it run at idle while checking oil pressure and volt reading.
It’s not unusual with smoke from the exhaust system just after start-up but this will stop
once the engine reaches operating temperature. Glow system will automatically afterglow.
Recommended cruising rpm for all Marinediesel engines is 2700-3200rpm although the
maximum rated effect is at a higher rpm. It is necessary to choose a propeller that will
allow the engine to reach maximum engine rpm at WOT to not inflict unnecessary load on
the engine, which could effect longevity and void warranty. Do not exceed maximum
recommended engine rpm as the pump reduces the amount of injected diesel after this rpm
and engine power drops quickly.
Winter storage
xOil system
Change oil on the supercharger (only SC models without commercial SC cooling), se
technical maintenance specifications. Drain the oil from the engine, either by removing
the oil plug in the oil pan or by a suction tube down the dipstick tube; remember it’s
always recommended to do this when the engine is at operating temperature. Tighten the
plug, clean the oil dipstick and reinsert it in the tube. Then remove the oil filter and
replace it with a new unit (don’t forget to prelubricate the seal ring on the filter and prefill
the filter with oil) tighten hard with manual power. Refill the engine with new oil
according to technical maintenance specifications. Check the oil level on the dipstick and
if necessary add more oil to reach the correct oil level. Start the engine and run it for a few
minutes so that the new oil can lubricate all moving parts. Turn off the engine and recheck
the oil level on the dipstick, again add more oil if necessary.
xFuel system
Check all hoses, clamps and fittings for leakage and wear, replace if necessary. Make sure
the fuel tank is full to prevent water contamination. Add “water repellent” isopropanol to
the fuel system. Remove and replace the fuel filter.
xCooling – system
Start the engine and run antifreeze mix through the raw water system. Check the freeze
protection of antifreeze in the freshwater cooling system. If you need to add antifreeze
make sure you allow the engine to run up to operating temperature allowing the

4
thermostat to open and mix the added antifreeze. Never use more than 50% antifreeze.
Turn off the engine and drain the raw-water system. At the same time remove the impeller
from the impeller pump. Check all hoses, clamps and fittings for wear and leakage,
replace if necessary. The heat exchanger, intercooler (SC models only) and oil cooler are
exposed to raw water and should be inspected for corrosion that could lead to engine
failure. It is recommended that the raw-water cooling system be cleaned and flushed every
500 hours or at least every two years.
xExhaust system
When the winter service is completed make sure all exhaust outlets and the air filter are
sealed to prevent moist/salt air from entering the engine.
xElectrical System
Remove and clean the battery/batteries. Also clean the battery cables and connecting
poles. Store battery in a cold/dry environment (never below 0C/32F) and keep it fully
charged.
Procedures after winter storage
xExhaust System
Remove all winter-storage-seals from exhaust and intake system.
xElectrical System
Reconnect the fully charged battery/batteries and tighten/lubricate the connectors. Check
the condition of the serpentine drive system belt; replace if worn or dry.
xCooling system
Recheck that all hoses and fittings in the raw-water system are connected and replace the
impeller (be careful not to scuff the impeller, use grease). Prime the raw-water system to
prevent overheating of the impeller at start-up.
xAir filter
Replace with new filter unit..
xStart-up
See starting procedures on page 3. Check for leakage of oil, fuel and water. Also check the
oil level on the dipstick, if necessary fill up with oil. Let the engine idle up to operating

5
temperature before usage or shutdown. When the operating temperature is achieved, again
check for leaking fluids.
Periodic maintenance - see separate Marinediesel Service book.
Periodic maintenance important notes
Periodic oil change on the supercharger (Only SC-models). USE ONLY Marinediesel
High Performance Supercharger oil. Do NOT overfill, correct level is critical. (Low level
can cause gear failure, high level can cause drive coupling failure)
Technical maintenance specifications
xRecommended engine oil: DO NOT USE SYNTHETIC OIL, use 15W/40 API: CH-
4, CG-4, CF-4, CF/SJ. Fill with 7,5 litres (including filter)
Warranty (
I. Marinediesel Sweden AB warrants each new production MarineDiesel Engine and Accessories attached thereto (here after referred to as “Product”),
manufactured by Marinediesel Sweden AB (hereafter referred to as the “Company”), to be free from defects in material and workmanship, but only
when the customer purchases or obtains pre-delivery service from a Dealer authorized by us to distribute MarineDiesel product in the country in
which the sale or pre-delivery service occurred. This warranty shall apply only to pleasure craft and light-duty craft applications.
II. This warranty shall become effective upon the date of sale to the first purchaser or user of the Product and receipt by MarineDiesel of a completed
Sea Trial Registration Form. The warranty period for standard engines (non RPM models) Pleasure Craft applications is one (1) year from the
date of sale to the first purchaser or user of the product or the
accumulation of 1500 hrs whichever occurs first. The warranty period for RPM series engines is one (1) year from date of sale to the first
purchaser or user of the product, or the accumulation of 750 hours of engine operation, whichever occurs first. The warranty period
for Light-Duty Craft applications is one (1) year from date of sale to the first purchaser or user of the product, or the accumulation of
750 hours of engine operation, whichever occurs first. The unused period of the applicable warranty, if any, is transferable to subsequent
purchasers only if the required maintenance records have been recorded by an authorized dealer. If the law applicable in the Country, State or
Province where the product is sold prohibits limitation of warranty coverage to one (1) years, then the warranty shall be the minimum
period required by law. For purposes of this warranty Pleasure Craft is defined as a recreational planing craft used only and
exclusively for pleasure and recreation. Light-Duty Craft is defined as a planing hull vessel used in any law enforcement,
commercial, or professional entertainment activity, or used in any enterprise or venture in which revenue in any amount is generated directly or
indirectly. The warranty will provide in the First Year: Parts and Labor. In no case will the warranty cover the cost of removing or
installing the engine in the boat, pulling the boat out of the
water, lifts or other associated incidental costs see item VII.
III. To validate the warranty, the “Warranty Registration Form”, and Pre-Delivery Inspection information included with each Product, must be properly
completed by the selling dealer and forwarded immediately after the Sea-Trial to Marinediesel Sweden AB, Metallgatan 6, 262 72 Engelholm
Sweden.
IV. Purchaser must provide proof of purchase and substantiate the original date of sale and delivery by presenting to the dealer, authorized to service the
Product, the original purchaser’s copy of the “Owner Warranty Registration Card”. If either of these items is not available, purchaser must provide a
copy of the original purchaser’s “Bill of Sale” (Sales Contract) for the Product to be serviced. Warranty claims will not be accepted by the dealer
until the original date of sale/delivery and Product serial number can be verified.
V. It is a condition for the continuation of this warranty that the Product be taken to an authorized Marinediesel Service Dealer, after 100 hours of
engine operation, but not later than 150 hours, for required checks and adjustments. A copy of the dealer service work order must be retained as
evidence of the completion of this requirement. This is an owner expense.
VI. Since this warranty applies to defects in material or workmanship, it does not apply to normal wear, adjustments, tune-ups or to damage caused by:
1) Neglect, lack of maintenance, accident, abnormal operation, improper installation or service;
2) Use of a propeller not properly suited to application/boat load or, failure to follow instructions in applicable service and warranty information
manuals or operation and maintenance manual;
3) As applied to twin installation vessels; continual operation of the vessel on only one engine in any condition other than an emergency
situation.
4) Use of an accessory or part not manufactured or sold by us;
5) Operation with fuels, oils, lubricants or coolants/ coolant additives which are not suitable for use with the Product or recommended by us;
6) Participating in or preparing for racing or other competitive activity;
7) Alteration or removal of parts;
8) Water entering engine cylinder/s through the exhaust system or air intake system;
9) Use or operation of the product in a manner inconsistent with the “Recommended Operation/Duty Cycle” section of the Operation and
Maintenance Manual.
10) Engine cooling system overheating.
11) Glow Plug Failure
VII. Reasonable access must be provided to the Product for warranty service. This warranty will not apply to:

6
1) Haul-out, launch, towing and storage charges, telephone or rental charges of any type, inconvenience, or loss of time or income, or other
consequential damages or dealer errors.
2) Removal and/or replacement of boat partitions or material because of boat design for necessary access to the Product.
VIII. Claim shall be made under this warranty by delivering the Product for inspection to a Marinediesel dealer authorized to service the Product. If
purchaser cannot deliver Product to such authorized dealer, he may give notice in writing to the Company . We shall then arrange for the inspection
and repair, provided such service is covered under this warranty. Purchaser shall pay for all related transportation charges and/ or travel time. If the
service is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.
Any product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid
IX. Our obligation under this warranty shall be limited to repairing a defective part or, at our option, refunding the purchase price or replacing such part
or parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this warranty. The repair
or replacement of parts, or the performance of service, under this warranty, does not extend the period of this warranty beyond its original expiration
date. Company reserves the right to improve the design of any Product without assuming any obligation to modify any Product previously
manufactured.
X. This warranty does not imply coverage for other manufacturers products used in combination with company products. Other manufacturer’s
products used in conjunction with Company’s Product’s are warranted at their own discretion and specifically as indicated by each specific
manufacturer.
XI. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY.
WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY. IMPLIED
WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY. SOME STATES OR COUNTRIES DO NOT ALLOW
LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL
OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU.
XII. In the event of any litigation with respect to the purchased product the parties agree the law for the country of Sweden
shall apply. Further, the parties agree such litigation shall lie within the appropriate court in Sweden.
*In the event that a warranty claim is required outside the country of Sweden, there may be additional charges not covered under
warranty based on local practices and conditions, such as but not limited to freight, insurance, taxes license fees, import duties,
and any and all other financial chares, including those levied by governments, states, territories, and their respective agencies
which will be the responsibility of the purchaser.
XIII. This warranty gives you specific legal rights and you may also have other legal rights, which vary, from state to state and country to country
Dealer & Service directory
FOR LATEST UPDATE WE REFER TO WWW.MARINEDIESEL.NU
Exhaust Manifolds
The MD exhaust manifolds are made of high quality cast aluminium that is heat treated,
anodized, vacuum injected and powder coated for maximum corrosion resistance. Each
exhaust manifold mounts to the cylinder head with a metric (M10X35) stainless steel hexagon
socket head bolts using Loctite 518 sealant. See picture below.

7
The raiser bolts on to the exhaust manifold using four metric (M10X30) stainless steel bolts,
torque to 30Nm using Loctite 518 sealant and high temp flange sealant on both sides of the
gasket. See picture below
Supercharger and Intercooler System
Air induction on Marinediesel SC-engines includes the following parts:
xAir intake duct, intake silencer and air filter assembly
xSupercharger assembly
xIntake assembly with integrated CuNi intercooler
xCrankcase ventilation system
Air intake duct and air filter assembly
Outside air enters the induction system through a filter located on the intake silencer inlet (see
picture below). This is a bonded cotton/wire mesh filter material and should be cleaned and
replaced according to service intervals (see service book). The air filter element mounts to the
intake silencer inlet with a clamp. The intake silencer mounts to the intake adaptor on the
supercharger with a hose and clamps as well as a bolted bracket by the air filter according to
pictures below.
Water passage gasket
Raiser bolts

8
Air intake adaptor mounts with 6pcs M8 X 25 hexagon socket head bolts.
Clamps
CDR valve Bolted
bracket

9
Supercharger assembly
The supercharger assembly connects to the intake manifold using a gasket and 7 pcs M8 X 25
hexagon socket head bolts, torque to 22 Nm, seal with Loctite 270, picture below.
Intake assembly with integrated CuNi intercooler
gasket

10
The intercooler mounts into the rear section of the intake manifold and is then covered by
a bronze lid which incorporated an o-ring for sealing. At the end of the intercooler is the
intercooler tank that is covered by a rubber damper to ensure that the intercooler does not get
in contact with the casting of the intake manifold. Seal the surface between the intercooler
tank and the rubber damper with sicaflex or other to make sure it stays in position during
assembly.
Crankcase ventilation system
CDR valve
”Crankcase Depressure
Regulator”
Rubber damper on
Intercooler tank

11
Impeller Pump
Standard UV1 Commercial (high flow)
Raw water and fuel inlet connections
Please see installation section starting page 169 for further information
Fuel inlet
connection
Fuel return
connection
Raw water
connection

12
Oil filter relocator
The oil filter relocator is ordered as an option when ordering the engine. As it is supplied
separately it is essential that the oil lines and oil filter are prefilled with oil before starting the
engine. The lines should be connected as shown below. To check the function of the remote
filter feel the oil lines when engine is running, if they are warm the oil is circulating as it
should, if not, stop the engine and recheck the connections.
CONNECT FROM ENGINE ADAPTER ”1” TO REMOTE OIL FILTER BRACKET ”IN”
AND FROM ENGINE ADAPTER ”2” TO REMOTE OIL FILTER BRACKET ”OUT”. TO
CHECK THE CONNECTION MAKE SURE THAT THE OIL HOSES GET WARM WHEN
ENGINE IS RUNNING, IF THEY STAY COLD RECHECK CONNECTION.
WARNING!!!!!!!!!
BEFORE MOUNTING THE OIL FILTER, FILL THE OIL FILTER COMPLETELY
WITH OIL. THIS TO ENSURE THAT THE ENGINE GETS LUBRICATED DIRECT
FROM START-UP. USE LOCTITE 518 ON ALL CONNECTIONS TO PREVENT
LEAKAGE.
Water heater connections:
The water heater fitting is ordered as an option when ordering the engine. Contact your local
dealer.
IN
OUT
2
1
ENGINE REMOTE
FILTER BRACKET
OUT
IN