Crusader MP8.1L PARTS MANUAL

MARINE

ILLUSTRATED

PARTS MANUAL

MODEL MP8.1L

L510009

2001 - 2005 MY

10/07

This Page Was

Intentially

Left Blank

MODEL MP8.1L PARTS MANUAL - 1

Contents:

Symbols ................................................................................................................................... 2

Gasket and Decal Kit Numbers

Maintenance Item Part Numbers

Cylinder Block Assembly - Figure 1

Cylinder Head Assembly - Figure 2

Intake Manifold Assembly - Figure 3

Oil Pan and Oil Pump Assembly - Figure 4

Throttle Body Assemblies and Related Components - Figure 5

Remote Oil Filter Components (2001-2004) - Figure 6

Remote Oil Filter Components (2005) - Figure 7

Fuel Control Cell (FCC) Components (2001-2004) - Figure 8

Fuel Control Cell (FCC) Components (2005) - Figure 9

OLD Returnless Fuel System Components - Figure 10 (thru S/N 630206)

NEW Returnless Fuel System Components - Figure 11 (S/N 630207 thru present)

Heat Exchanger and Components (2001-2004) - Figure 12

Heat Exchanger and Components (2005) - Figure 13

Fresh Water Cooling System Components (Non-Heated Risers) (2001-2004) - Figure 14

Fresh Water Cooling System Components (Heated Risers) (2001-2004) - Figure 15

Fresh Water Cooling System Components (2005) - Figure 16

Raw Water Cooling System Components - Figure 17

Exhaust Manifold and Components - Figure 18

Raw Water Cooling Pump (2001-2004) - Figure 19

Raw Water Cooling Pump (2005) - Figure 20

Wiring Harness Assemblies and Senders - Figure 21

ECM and Relays (S/N 610000 thru 630396) - Figure 22

ECM and Relays (S/N 630397 and above) - Figure 23

ECM and Relays (2005) - Figure 24

Accessory Drive System Components (2001-2004) - Figure 25

Accessory Drive System Components (2005) - Figure 26

Starter Assembly Components - Figure 27

Engine and Transmission Mounts - Figure 28

Optional Engine and Transmission Mounts (OEM speciﬁ c) - Figure 29

Bellhousing Assembly - Figure 30

Transmission and Related Parts (Velvet Drive In-Line) - Figure 31

Transmission and Related Parts (Velvet Drive “V”-Drive) - Figure 32

Transmission and Related Parts (Velvet Drive 5000) - Figure 33

Transmission and Related Parts (Hurth Gear) - Figure 34

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CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 2

“TYPICAL VIEWS ARE SHOWN”

ENGINE ROTATION

Engine Rotation is identiﬁ ed as “RH” or “LH” with the engine model number. Rotation always is determined from the ﬂ ywheel end looking toward the front of the engine. In some instances, propeller shaft rotation may be opposite to that of the engine.

When ordering a replacement engine, production block or parts for the engine, be certain to check engine rotation. DO NOT rely on propeller rotation in order to determine engine rotation.

LEFT-HAND ROTATION is STANDARD ROTATION.

(Flywheel turns counterclockwise when viewed from ﬂ ywheel end of the engine.)

RIGHT-HAND ROTATION is OPPOSITE ROTATION.

(Flywheel turns clockwise when viewed from ﬂ ywheel end of the engine.)

HOW TO READ THIS PARTS BOOK:

ITEM PART NUMBER DESCRIPTION QUANTITY

1 RB001018 Base Engine Assembly, 8.1L 1

12 3 4

ITEM NUMBER - This number corresponds with the number in the exploded view on the facing page.

1

PART NUMBER - This is the designated part number for the particular component or assembly.

2

DESCRIPTION - This identiﬁ es what the component or assembly is.

3

QUANTITY - This refers to the number of pieces used.

4

======================================================================

Symbols shown throughout parts list are deﬁ ned here or on the bottom of the individual parts list page.

AR = As Required

OPT = Optional

NSS = Not Serviced Separately

NA = Not Available

SS = Single Station Control

DS = Dual Station Control

OS = Oversize

US = Undersize

TBD = To Be Determined

NI = Not Illustrated

======================================================================

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 3

REPLACEMENT PARTS:

WARNING:

Electrical, ignition and fuel system components on Crusader Engines are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize risks of ﬁ re or explosion.

Use of replacement electrical, ignition and fuel system components which do not comply with these rules and regulations could result in a ﬁ re or explosion hazard and should be avoided.

GASKET AND DECAL KIT NUMBERS:

Description Part Number

Complete Engine Overhaul Gasket Set TBD

Valve Grind Gasket Set TBD

Oil Pan Gasket Set RM0263

Intake Manifold Gasket Set RM0267

On Board Spare Parts Kit (FCC) RK173087

On Board Spare Parts Kit (RTNLSS) RK173087A

On Board Spare Parts Kit (MY ‘05, FCC) RK173087-05

On Board Spare Parts Kit (MY ‘05, RTNLSS) RK173087A-05

======================================================================

MAINTENANCE ITEM PART NUMBERS:

Description Part Number

Oil Filter 22679

Kit, Transmission Oil Filter (ZF) RP077011

Fuel Filter, screen, Pre-Filter R077012

Fuel Filter, screen,115 micron, Oberg R077013

Fuel Filter, screen, Pre-Filter RP077014

Fuel Filter, FCC RP080026

Fuel Filter, element, Racor 47047

Spark Plugs R030009

Spark Plug Wire Set RK120019

Accessory Drive Belt R066024

Accessory Drive Belt (MY ‘05) R066024A

Impeller Kit RP061017

Impeller Kit (MY ‘05) RP061022

Thermostat R026007

======================================================================

CHANGE NOTICE:

Change Pages Date Updated

23, 50-51, 64-65, 73 05/07

47 10/07

MARINE TRANSMISSIONS:

Crusader Engines are equipped with Velvet Drive or Hurth Transmissions or “V”-drives. If transmission parts are required, contact your dealer or closest Crusader Parts Distributor for required parts.

Parts manuals and overhaul manuals are available through Crusader Distributors.

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 4

CYLINDER BLOCK ASSEMBLY - FIGURE 1

19

17

5

20

21

22

23

44

24

54

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9B

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OR

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51

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48

50

PC81001_05

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 5

CYLINDER BLOCK ASSEMBLY - FIGURE 1

ITEM PART NUMBER DESCRIPTION QUANTITY

* RB001018 Base Engine Assembly, 8.1 STD, top mount starter

* RB001018A Base Engine Assembly, 8.1 STD, bottom mount starter

* RB001019 Base Engine Assembly, 8.1 HO, top mount starter

* RB001019A Base Engine Assembly, 8.1 HO, bottom mount starter

1 R017080 Nut, connecting rod cap 16

2 R007026 Bearing Set, connecting rod (STD) 8

3 R009195 Bolt, connecting rod cap 16

4 RA013015A Piston and Connecting Rod Assembly (LH/STD) 4

4 RA013015B Piston and Connecting Rod Assembly (RH/STD) 4

5 R020033 Sensor, knock 2

6 NSS Cylinder Block

7 RA073001 Drive, oil pump 1

8 TBD Bolt, oil pump drive 1

9 TBD Plug, oil gallery

9A R024223 Adapter, oil pressure sensor (OEM speciﬁ c) AR

9B R020048 Sensor, oil pressure (CAN-Bus) (OEM speciﬁ c) AR

10 R022021 Pin, cylinder head locating 4

11 R015012 Ring Set, piston (STD) 8

12 R020034 Sensor, crankshaft position 1

12 R020034 Sensor, crankshaft position 1 (S/N 640118 and above)

13 TBD Bolt, crankshaft position sensor 1

14 R069065 Plug, camshaft 1

15 R051039B Bearing, camshaft #2 and #5 2

16 R051039A Bearing, camshaft #3 and #4 2

17 TBD Plug, engine block oil gallery 4

18 TBD Valve, oil bypass 1

19 R079048 Fitting, oil bypass adapter 1

20 R079065 Adapter, oil bypass 8.1L 1

21 R024183 Connector, engine oil cooler hose 2

22 R069070 Plug, engine block coolant drain hole 2

23 TBD Plug, engine block coolant drain hole 1

24 R007028 Bearing

25 TBD Pin, ﬂ ywheel locating 2

26 R047224 Seal, crankshaft rear oil 1

27 R007027 Bearing, crankshaft (STD) 4

28 R009196 Bolt, crankshaft bearing cap 10

29 R012023 Deﬂ ector, crankshaft oil 1

30 TBD Nut, crankshaft oil deﬂ ector

31 R031032 Stud, crankshaft bearing cap 9

32 TBD Pin, crankshaft balancer locating 1

, crankshaft (thrust) 1

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 6

CYLINDER BLOCK ASSEMBLY (cont’d) - FIGURE 1

19

17

20

54

55

25

26

5

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24

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44

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9B

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OR

9A

53

16

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45

9

52

51

43

42

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46

47

48

50

PC81001_05

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 7

CYLINDER BLOCK ASSEMBLY (cont’d) - FIGURE 1

ITEM PART NUMBER DESCRIPTION QUANTITY

33 RM0264 Gasket, engine front cover 1

34 R004011 Cover, engine front cover (includes gasket and seal) 1

34 TBD Cover, engine front cover (includes gasket and seal, S/N 640118 and above) 1

35 R047225 Seal, crankshaft front oil 1

36 R064015 Balancer, crankshaft (STD - ‘01-’04) (HO - ‘03-’04) (Use with crankshaft R006029) 1

36 R064015A Balancer, crankshaft (HO - ‘01-’02) (Use with crankshaft R006030) 1

37 R096146 Washer, crankshaft balancer 1

38 TBD Bolt, crankshaft balancer 1

39 TBD Bolt, camshaft position sensor 1

40 R020035 Sensor, camshaft position sensor 1

40 R020035A Sensor, camshaft position sensor 1 (S/N 640118 and above)

41 TBD Bolt, engine front cover 6

42 R054039 Sprocket, crankshaft 1

42 TBD Sprocket, crankshaft 1 (S/N 640118 and above)

43 R006029 Crankshaft (STD - ‘01-’04) (HO - ‘03-’04) (Use with balancer R064015) 1

43 R006030 Crankshaft (HO - ‘01-’02) (Use with balancer R064015A) 1

44 R022022 Pin, engine front cover locating 1

45 R051039A Bearing, camshaft #1 1

46 R022022 Pin, camshaft sprocket locating 1

47 TBD Bolt, camshaft retaining 2

48 R054040 Sprocket, camshaft 1

49 R055016 Chain, camshaft timing 1

50 TBD Bolt, camshaft sprocket 3

51 R109050 Retainer, camshaft 1

52 RA050023 Camshaft, engine (STD) 1

52 RA050024 Camshaft, engine (HO) 1

53 TBD Plug, engine block oil gallery 3

54 TBD Bolt, ﬂ ywheel to crankshaft 6

55 RA138015 Flywheel Assembly, (Bottom Mount Starter) 1

55 RA138014 Flywheel Assembly, (Top Mount Starter) 1

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 8

CYLINDER HEAD ASSEMBLY - FIGURE 2

4

3

6

6A

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2

1

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5

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1717

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1919

19

20

PC81002

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 9

CYLINDER HEAD ASSEMBLY - FIGURE 2

ITEM PART NUMBER DESCRIPTION QUANTITY

1 R033013 Cover, rocker, OLD coils 2 1 TBD Cover, rocker, NEW coils 2 2 R127096 Retainer, ignition coil wire harness 4 3 R121074 Wire Harness, ignition coils (OLD) 2 3 R121074A Wire Harness, ignition coils (NEW) 2 4 TBD Bolt, ignition coil wire harness retaining 2 5 TBD Bolt, ignition coil retaining 16 6 R117012 Coil, ignition (OLD) 8

(Standard - prior to S/N 621056) (H.O. - prior to S/N 630082)

6A R117013 Coil, ignition (NEW) 8 (Standard - S/N 621056 and above) (H.O. - S/N 630082 and above)

7 R009200 Bolt, rocker cover retaining 14 8 R094039 Grommet, rocker cover retaining 14 9 RM0261 Gasket, rocker cover 2 10 R039021 Push Rod, intake 8 11 R039022 Push Rod, exhaust 8 12 R017079 Nut, rocker arm attaching 16 13 R038012 Ball, rocker arm 16 14 R038018 Rocker Arm, valve 16 15 R095039 Stud, push rod guide attaching 16 16 R037003 Guide, pushrod 8 17 R009197 Bolt, cylinder head to block (long) 24 18 R009198 Bolt, cylinder head to block (medium) 4 19 R009199 Bolt, cylinder head to block (short) 8 20 RK120019 Spark Plug Wire Set 1 21 R030009 Spark Plug 8 22 TBD Plug, pipe (1/2”) 2 23 R043033 Valve, intake (STD) 8 24 R043034 Valve, exhaust (STD) 8 25 RM0262B Gasket, cylinder head (RH) 1 25 RM0262A Gasket, cylinder head (LH) 1 26 R003014 Cylinder Head Assembly (RH) 1 26 TBD Cylinder Head Assembly (RH) 1 (S/N 640118 and above) 26 R003015 Cylinder Head Assembly (LH) 1 26 TBD Cylinder Head Assembly (LH) (S/N 640118 and above) 27 R049013 Rotator, valve 16 28 R047226 Seal, valve stem 16 29 R046049 Valve Spring Assembly 16 30 R049014 Cap, valve spring 16 31 R049010 Retainer, valve stem 32

1

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 10

INTAKE MANIFOLD ASSEMBLY - FIGURE 3

37

34

27A

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19

XXXXXX XXXXXXX XXXXXXXXX

XXXXXXXXX

XXXXXXX XXXXXX

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XXX XX

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1

2

6

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18

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14

PC81003_05

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 11

INTAKE MANIFOLD ASSEMBLY - FIGURE 3

ITEM PART NUMBER DESCRIPTION QUANTITY

1 R121075 Wire Harness, fuel injectors 1 2 RA086001 Fuel Rail Assembly 1 2 RA086001A Fuel Rail Assembly (2005 FCC Fuel System) AR 3 TBD Bolt, MAP sensor retaining 1 4 RM0265 Gasket, EGR blockoff cover 1 5 TBD Cover, EGR blockoff 1 6 TBD Nut, EGR blockoff cover attaching 2 7 TBD Stud, EGR blockoff cover attaching 2 8 TBD Plug, intake manifold core hole 1 9 20237 Hose, fuel pressure regulator vacuum 1 10 RM0267 Gasket Set, intake manifold 1 11 R037004 Guide, valve lifter 8 12 R040004 Lifter, valve 16 13 TBD Bolt, valve lifter retainer 4 14 R090253 Retainer, valve lifter 1 15 R012025 Guard, oil splash - lifter 1 16 R002022 Intake Manifold 1 16 TBD Intake Manifold (S/N 640118 and above) 1 17 RM0251 Gasket, throttle body mounting 1 18 RA035036 Throttle Body, mechanical throttle (STD) 1 18 RA035036A Throttle Body, mechanical throttle (HO) 1 18 RA035041 Throttle Body, electronic 1 19 49027 Nut, throttle body attaching 3 20 TBD Stud, throttle body mounting 3 21 R009201 Bolt, intake manifold to cylinder head 10 21 TBD Bolt, intake manifold to cylinder head 10

(S/N 640118 and above) 22 TBD Seal, MAP sensor 1 23 R020036 MAP Sensor 1 24 RA087006 Fuel Injector Assembly 8 25 R127097 Retainer, fuel injector to fuel rail 8 26 RK047227 O-Ring, kit fuel injector 8 27 R034046 Riser, oil ﬁ ll (‘01-’02 MY) 1 27 R034046A Riser, oil ﬁ ll (‘03 MY to present) 1 27A R034046B Riser, oil ﬁ ll (MY ‘05, OEM speciﬁ c) 1 28 NSS O-Ring, oil ﬁ ll riser cap 1

29 R034038A Cap, oil ﬁ ll riser (‘01-’02 MY) 1 29 R034038B Cap, oil ﬁ ll riser (‘03 MY to present) 1

30 R143137 Decal, oil ﬁ ll riser cap 1 31 98222020 Bolt, oil ﬁ ll riser attaching 1 32 TBD Stud, fuel rail assembly attaching 3 33 R088001 Regulator, fuel pressure 1 34 R060057 Cover, engine 1 35 99223030 Bolt, engine cover attaching 4 36 R143130 Decal, “CAPTAIN’S CHOICE” AR 36 R143130A Decal, “CRUSADER ENGINES” AR 37 R143133 Decal, “8.1 MPI” (red/silver) AR 37 R143133A Decal, “8.1 MPI” (black/silver) AR 37 R143134 Decal, “8.1 HO” (red/silver) AR

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 12

OIL PAN and OIL PUMP ASSEMBLY - FIGURE 4

15

16

12

13

1

2

14

4

3

5

6

7

9

8

10

11

PC81004

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 13

OIL PAN and OIL PUMP ASSEMBLY - FIGURE 4

ITEM PART NUMBER DESCRIPTION QUANTITY

1 R041068 Dipstick, oil level (Level) 1

1 R041069 Dipstick, oil level (Angled) 1

2 R127015 Clamp, dipstick tube attaching 2

3 98443025 Bolt, dipstick tube attaching 2

4 93940000 Lockwasher, dipstick tube attaching bolt 2

5 R041072 Dipstick Tube 2

6 TBD Bolt, oil pan bafﬂ e 12

7 R012026 Bafﬂ e, oil pan 1

8 R024017 Elbow, dipstick tube to oil pan 2

9 R024200 Adapter, dipstick elbow to oil pan 2

10 R005023 Oil Pan 1

11 TBD Bolt, oil pan mounting 20

12 RM0263 Gasket, oil pan 1

13 TBD Bolt, oil pump mounting 2

14 R022022 Pin, dowel - oil pump aligning 1

15 RA070017 Oil Pump Assembly 1

16 R058055 Shaft, oil pump to oil drive 1

NI TBD Kit, oil drain 1

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 14

THROTTLE BODY and RELATED COMPONENTS - FIGURE 5

1

2

4

9

7

8

3

5

6

21

18

19

20

14

DUAL STATION

15

17

16

10

11

12

13

SINGLE STATION

PC81005

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 15

THROTTLE BODY and RELATED COMPONENTS - FIGURE 5

ITEM PART NUMBER DESCRIPTION QUANTITY

1 R145021 Flame Arrestor 1

2 RS3857 Clamp, retaining 1

3 RA035036 Throttle Body Assembly, STD 1

3 RA035036A Throttle Body Assembly, HO 1

4 TBD O-Ring Seal, idle air control valve 1

5 TBD Screw, IAC valve attaching 2

6 R084003 Valve, idle air control 1

7 R020041 Sensor, throttle position 1

8 TBD Screw, TP sensor attaching 2

9 TBD O-Ring Seal, throttle position sensor 1

10 RS1078 Nut, retaining bolt 1

11 R090230 Throttle Arm, throttle body 1

12 RS0251 Bolt, throttle arm retaining 1

13 R178014 Ball Joint Assembly, cable attaching (single) 1

14 22978 Pivot Pin, cable attaching (dual) 1

15 23235 Cable Attaching Kit, (dual) AR

16 R090086 Cable Clip, throttle attaching (single) 1

17 RS5122 Bolt, cable clip mounting 2

18 98223016 Bolt, bracket mounting 1

19 93920000 Lockwasher, bracket mounting 1

20 R090229 Throttle Bracket, intake 1

21 RS2055 Locking Nut, cable clip mounting bolt 2

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 16

1

3

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PC81006

DO NOT

REMOVE

8

7

6

REMOTE OIL FILTER COMPONENTS (2001-2004) - FIGURE 6

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 17

REMOTE OIL FILTER COMPONENTS (2001-2004) - FIGURE 6

ITEM PART NUMBER DESCRIPTION QUANTITY

1 R024150 Fitting, 45 degree 1

2 RA045121 Hose Assembly, cooler to ﬁ lter header 1

3 R024184 Fitting, 90 degree 1

4 R147035A Cooler Assembly 1

5 RA045120A Hose Assembly, adapter to cooler 1

6 RS1078 Nut, strap clamp attaching 1

7 98315 Clamp, strap 1

8 90105125 Bolt, strap clamp attaching 1

9 95011000 Nut, sender terminal 1

10 95300300 Lockwasher, sender terminal 1

11 92300200 Washer, sender terminal 1

12 R020001 Sender, oil pressure (SS) 1

12 727046 Sender, oil pressure (DS) AR

13 R024145 Tee, sender attaching 1

14 R020015A Switch, oil pressure (SS) 1

15 RS3677 Adapter, sender attaching tee 1

16 R079048 Fitting, oil bypass adapter 1

17 R079065 Adapter, oil bypass 1

18 R143135 Decal, oil bypass adapter 1

19 R024183 Fitting, remote oil ﬁ lter hose 2

20 RA045120 Hose Assembly, adapter to ﬁ lter header 1

21 22679 Filter, oil 1

22 R024203 Nipple, header ﬁ lter adapter 1

23 R079066 Oil Filter Header 1

24 R090226 Bracket, oil ﬁ lter mounting 1

25 93930000 Lockwasher, header mounting bolt 3

26 99333020 Bolt, header mounting 3

27 R047245 O-Ring, oil line 2

28 R090194 Bracket, oil cooler mounting 1

29 R171007 Strap, cooler mounting 2

30 RS5115 Bolt

, cooler mounting strap 2

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 18

5

1

6

7

10

8

9

2

3

4

DO NOT

REMOVE

11

13

12

17

14

15

16

18

19

24

23

22

21

26

31

27

28

25

30

29

w/ Returnless Fuel System

29

31

32

30

33

34

35

36

PC81006-C06

20

37

38

REMOTE OIL FILTER COMPONENTS (2005) - FIGURE 7

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 19

REMOTE OIL FILTER COMPONENTS (2005) - FIGURE 7

ITEM PART NUMBER DESCRIPTION QUANTITY

1 R079066 Oil Filter Header 1

2 93930000 Lockwasher, header mounting bolt 3

3 99333020 Bolt, header mounting 3

4 R143175 Decal, “Caution Hot” 1

5 R047245 O-Ring, oil line 2

6 R024203 Nipple, header ﬁ lter adapter 1

7 22679 Filter, oil 1

8 RA045155A Hose Assembly, block to ﬁ lter header 1

8 RA045120D Hose Assembly, block to ﬁ lter header (Returnless Fuel System) 1

9 RA045155A Hose Assembly, cooler to ﬁ lter header 1

9 RA045120D Hose Assembly, cooler to ﬁ lter header (Returnless Fuel System) 1

10 R090258 Bracket, heat exchanger 1

11 95011000 Nut, sender terminal 1

12 95300300 Lockwasher, sender terminal 1

13 92300200 Washer, sender terminal 1

14 R020001 Sender, oil pressure (SS) 1

14 727046 Sender, oil pressure (DS) AR

15 R024145 Tee, sender attaching 1

16 R020015A Switch, oil pressure (SS) 1

17 RS3677 Adapter, sender attaching tee 1

18 R079048 Fitting, oil bypass adapter 1

19 R079065 Adapter, oil bypass 1

20 R143135 Decal, oil bypass adapter 1

21 R024183 Fitting, straight 2

22 RA045121A Hose Assembly, cooler to block 1

23 R147049 Cooler Assembly 1

24 R024184 Fitting, 90 degree 2

25 R090013A Bracket, oil cooler mounting 1

26 RS0302 Bolt, oil cooler attaching 1

27 RS2180 Lockwasher

28 RS2058 Nut, oil cooler attaching 1

29 R090010 Clamp, oil cooler mounting 1

30 RS0256 Bolt, oil cooler clamp 1

31 RS1028 Nut, oil cooler clamp 1

32 90318275 Bolt, oil cooler clamp to bracket attaching 1

33 9330000 Lockwasher, clamp to bracket attaching 1

34 95310300 Nut, oil cooler clamp to bracket attaching 1

35 R090304A Bracket, oil cooler attaching (Rtrnlss fuel sys.) 1

35 R090233A Bracket, oil cooler attaching (OEM speciﬁ c) 1

36 98443025 Bolt, bracket attaching 1

37 93940000 Lockwasher, bracket attaching 1

38 R024183 Fitting, straight (Returnless Fuel System) 1

, oil cooler attaching 1

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 20

12

11

13

14

15

16

17

18

19

21

20

22

11

9

10

7

8

6

25

3

4

5

1

2

24

23

PC81007

26

25

28

29

27

30

31

32

33

34

FUEL CONTROL CELL (FCC) COMPONENTS (2001-2004) - FIGURE 8

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 21

FUEL CONTROL CELL (FCC) COMPONENTS (2001-2004) - FIGURE 8

ITEM PART NUMBER DESCRIPTION QUANTITY

1 RA085090 Hose Assembly, FCC to fuel rail (inlet) 1

2 RA085091 Hose Assembly, fuel rail to FCC (return) 1

3 RS0302 Bolt, FCC mounting 3

4 RS2180 Lockwasher, FCC mounting 3

5 R090227 Bracket, FCC mounting 1

6 R090228 Bracket, low-pressure fuel pump mounting 1

7 RS1521L Locking Nut, fuel pump terminal 3

8 R096142 Washer, fuel pump mounting 3

9 R094035A Grommet, mounting bracket 3

10 R096141 Washer, fuel pump mounting 3

11 R024197 Fitting, 45 degree 2

12 RA085071B Hose Assembly, FCC to fuel return line adapter 1

13 R024062A Adapter, fuel return line 1

14 R090234 Bracket, fuel ﬁ lter mounting 1

15 R024196 Fitting, fuel inlet 1

16 RS1529 Nut, fuel ﬁ lter mounting 1

17 RS2181 Washer, fuel ﬁ lter mounting 1

18 RA077013 Filter, fuel (115 micron) 1

NI R077013 Filter, screen (115 micron) 1

19 R024198 Fitting, 45 degree 1

20 RS2675 Washer 1

21 TBD Locking Nut 1

22 RA085071 Hose Assembly, ﬁ lter to low-pressure pump 1

23 RA080018 Fuel Pump, low-pressure 1

24 RA085070 Hose Assembly, low-pressure pump to FCC 1

25 RA080029 Fuel Control Cell (FCC) Assembly 1

26 RP080026 Fuel Filter, FCC Assembly 1

27 R047214 O’Ring, FCC seal 1

28 RA080027 Fuel Pump, high pressure 1

29 R127087 Clamp, Oetiker 2

30 R045098 Hose, 5/16 I.D. - 1/2 O.D. 1

31 R024175 Fitting

32 R024163A Fitting, fuel line 1

33 R035031 Fitting, fuel pressure, Schrader valve 1

34 R127100 Retainer, fuel line 2

NI R034041 Cap, Schrader valve 1

, fuel line 1

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 22

FUEL CONTROL CELL (FCC) COMPONENTS (2005)- FIGURE 9

2A

5

4

3

6

9

7

8

10

13

12

11

14

15

36

16A

20

19

32

33

37

38

34

33

39

18

17

16B

1

2A

2

35

2C

2B

31

30

23

24

29

25

26

42

27

28

21

22

42

41

4

5

40

1

PC81007_05

L510009 CRUSADER MP8.1L

MODEL MP8.1L PARTS MANUAL - 23

FUEL CONTROL CELL (FCC) COMPONENTS (2005) - FIGURE 9

ITEM PART NUMBER DESCRIPTION QUANTITY

1 RA080030A Fuel Control Cell Assembly 1 2 R121085A Harness, 1-piece, FCC pass through 1

(1-piece harness does not retro ﬁ t for 2-piece harness) 2A 7172040 Connector, W/P 2-way Female 1

2B R012030 Bafﬂ e, FCC used w/1-piece harness 1 2C 91620025 Screw, self tapping, bafﬂ e/1-piece harness retaining 2 3 R024175 Fitting, 1/4 NPT X SAE 1 4 R024225 Fitting, 1/4 NPT to Hose (return to tank) 1 4 R024224 Fitting, 1/4 NPT to SAE (return to tank) AR 5 R024163 Fitting, 1/4 NPT X SAE (from LPFP) 1 6 R088004 Regulator, fuel pressure (FCC System Only) 1 7 R048070 Retainer, fuel pressure regulator 1 8 R045098B Hose, 5/16id X 1/2od X 2 1/2 1 9 R127087 Clamp, Oetiker, 5/8 2 10 RA080027 Pump, high pressure fuel 1 11 R080026 Filter, fuel (FCC) 1 NI RP080026 Kit, FCC ﬁ lter and O-rings 1 12 R171010 Clamp, FCC 1 13 R128002 Cover, T-bolt end 1 14 R143112A Decal, FCC 1 15 RS3554 Plug, pipe, hex head, 1/8 1 16A RA121060 Harness, FCC Feed through 1 16B RA121061A Harness, FCC internal 1 17 R024219 Fitting, 1/8 NPT X 5/16 Barb 1 18 R047241 O-Ring, FCC sealing 1 19 RS3550 Plug, pipe, hex socket, 1/4 1 20 R127100 Retainer, fuel line 1 21 RA085090 Hose Assembly, FCC to fuel rail (inlet) 1 22 90384075 Bolt, FCC attaching 3 23 R090227 Bracket, FCC mounting 1 24 R090228A Bracket, low-pressure fuel pump mounting 1 25 RS1521L Locking Nut, low-pressure fuel pump 3 26 R096142 Washer, ﬂ at, mounting, upper 3 27 R094035A 28 R096141 Washer, fuel pump mounting, lower 3 29 RS0251 Bolt, pre-ﬁ lter bracket attaching 2 30 RS1078 Nut, w/lockwasher, pre-ﬁ lter bracket attaching 2 31 R090272 Bracket, pre-ﬁ lter mounting 1 32 R024192 Fitting, 90 degree, LPFP 2 33 R094040 Isolator, rubber, w/ adhesive 1 34 RS3858 Clamp, pre-ﬁ lter 1 ¼” 1 35 R143174 Decal, pre-ﬁ lter 1 36 30603 Fitting, fuel inlet, pre-ﬁ lter, 3/8 NPT X 1/2 SAE AR 36 R024218 Fitting, fuel inlet, pre-ﬁ lter, 3/8 NPT X 1/2 hose barb 1 37 RA077014 Fuel Pre-ﬁ lter Assembly, 150 micron 1 38 RP077014 Kit, fuel ﬁ lter and seal 1 39 RA080018 Fuel Pump, low-pressure 1 40 RA085070 Hose Assembly, low-pressure pump to FCC 1 41 98443025 Bolt, FCC/LPFP bracket attaching, block 4 42 93940000 Lockwasher, FCC/LPFP bracket attaching, block 4 NI R143114 Decal, Warning, fuel leaks 1

Grommet, isolator 3

CRUSADER MP8.1L L510009

MODEL MP8.1L PARTS MANUAL - 24

OLD RETURNLESS FUEL SYSTEM COMPONENTS - FIGURE 10 (thru S/N 630206)

28

29

30

27

31

26

32

25

33

35

24

34

23

10

11

18

21

22

20

19

17

16

15

14

13

12

7

6

9

8

11

10

21

18

19

11

33

36

33

37

2

3

42

41

40

39

38

43

20

45

48

44

46

1

3

2

45

NIO

O

N

G TER A

G

RAW-

W

DRAI

PLU

IN Z

E

D

E

R

E

A

R N I

S

F A

E

W

R

O DR

U

L E

E

AT

B

R

T

L

E

S

L

P

U

A

M

F M

E

R

T

TO

Fuel

E

R

L

D

Cooler

E

O

E

V

T O

E

C

N

C

E

IS

P

H

X H T

W

E

47

ARNING W

L510009 CRUSADER MP8.1L

Crusader MP8.1L PARTS MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual