Crusader MP 5.0L, MP 5.7L, MP 6.0L, MP 8.1L STD, MP 8.1L HO Product Installation Manual

E N G I N E S

INSTALLATION MANUAL

PRODUCT

Retail Price $12.00

03/07L510023-07

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Intentionally Left

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Welcome to the growing family of Crusader Marine Engines owners. We are delighted you have chosen Crusader
power for your boat and wish you many years of enjoyment.

When you chose Crusader, you selected the utmost in premium power for your boating application. Pleasurecraft
is the world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting edge technology.
Over the years, we have introduced many breakthrough innovations that quickly became industry standards. No
matter which Crusader model you purchased, you can be sure it is equipped with the latest in modern technology for
added performance and durability.

READ THIS MANUAL THOROUGHLY

Before you begin the installation of your new Crusader engine, READ THIS MANUAL CAREFULLY AND
COMPLETELY. There are many new and exciting features available with your new Crusader that you may wish to

take advantage of and plan for as you begin the installation of your new Crusader engine.

Crusader Sync-N-Cruz - Every new fuel injected Crusader engine is capable of twin engine synchronization and
cruise control with the addition of the Crusader Sync-N-Cruz Kit RF152007. This kit includes a harness and control
panel which provides for a very simple installation for plug and play operation. For twin engine applications, the
Master/Slave engine harness is required.

Crusader Engines has worked closely with FW Murphy who makes available multifunction digital displays, such as
PowerView and HelmView, plus a complete line of CAN Bus Instrumentation that are completely compatible with your
new Crusader engine. The Crusader Engines’ ECM-07 engine management system outputs J1939 and NEMA 2000
protocol messages that may be compatible with other manufacturers’ multifunction display equipment. Check with
the manufacturer of the display and / or instrument you are considering, prior to purchase, for compatibility with the
Crusader ECM-07 system.

Crusader Engines has taken care to develop a complete line of adapters and boat harnesses to make your new
installation as seamless as possible. Items available include adapters for engine to existing boat harness, twin engine
Master/Slave harness, engine alarm kit, electric fuel solenoid valves, and water separating fuel fi lters.

Please read this manual carefully and plan ahead. There may be additional items that you may wish to replace or
upgrade as you install your new Crusader engine. If you do not understand any portion of the manual or require
additional supplies or accessories, contact your Distributor/Dealer for clarifi cation or assistance.

The descriptions and specifi cations contained in this manual were in effect at the time of printing. Crusader Marine
Engines’ policy of continued improvement reserves the right to change specifi cations or design without notice and
without obligation.

This manual will cover the following Crusader engines:

Year Model

2007 5.0L MPI

2007 5.7L MPI

2007 6.0L MPI

2007 8.1L MPI

2007 8.1L MPI (HO)

2007 Classic 5.7L Carburetor

Part Number - L510023-07 Printed 03/07

TABLE OF CONTENTS

SECTION ...................................................................................................................……................................................ Page

General Information ….....……...……...……..........................................……...……...……...………......... 3

Engine Models …..............…...…............…...……...……..............……...……...……...……...………...... 3

Crusader Accessories

Engine Installation Accessories

Installation Supplies …...................…...……...……................................……...……...……...………......... 3

Installation Drawings

Engine and Transmission Combinations

Transmission Rotation …..............…...……...……...…................……...……...……...……...………....... 6-7

Gear Ratio Selection
Propeller Shaft / Coupling

Transmission and Propeller Rotation

Propeller Selection

Boat Construction …..............…...……..........……...…......................................…...……...………......... 12

Installation Requirements …...........…...……...……..........……...……...……...……...……...………......... 12

Instrumentation

Twin Engine Synchronization and Speed Control (Optional) ...........................……...…….................……....... 13

Master/Slave Wiring Connection

Engine Warning Kit (Optional) …....................…..................................……...……...….......………....... 14-15

Electrical System Precautions

Engine Harness Electrical Connector Identifi cation …........................….................…...…...……...……........ 17

Crusader Classic 5.7L Carburetor - Electrical System Precautions …....................….............……...……......... 18

Crusader Classic Installation Accessories …....................….......…...……...….............….....…...……......... 18

Crusader Classic Engine Wiring Diagram …....................….......…...……...…….........................……......... 19

Boat Adapter Harness Diagram …....................…................................…...……...……...……...……......... 20

Engine Boat Harnesses and Accessories Diagram …....................….......…...……...……...……...……......... 21

Crusader Boat Harness Wiring Diagram …....................….......…...........................……...……...……......... 22

Engine Speed Control/CAN-Bus Harness Diagram …....................….............……...……...……...……......... 23

Sync/Cruise Switch Panel Wiring Diagram …....................….................…...……...……...……...……......... 24

Crusader Boat Speed Control Harness Wiring Diagram ….............….......…...……...……...…..….……......... 25

Engine Compartment Ventilation …................…...…….........................……...……...…...……...……........ 26

Fuel Supply and Return Connections …............................................................................……...……........ 27

Fuel Inlet Restriction …..............…...…....…...……........................……...……...……...……...……......... 28

Fuel Lines …..............…...……...……...……...…….........................................….......……...……......... 28

Fuel System Pressure Check …................................................…...……...……...……...……...……......... 28

Gasoline Requirements …..............................................................................................……...……........ 29

Gasoline Containing Alcohol …..............…...…..............................……...……...……...……..................... 29

Fuel Stabilizer Recommendations for Ethanol Blended Fuel …...................................……...……...……......... 29

Fuel Filter Recommendations for Ethanol Blended Fuel …..............…...……...……...……...……...……......... 30

Exhaust System …...............................…...……....................…...……...……...……...……...……......... 31

Exhaust Risers …..............….....................……................…...……...……...……...……...……......... 31-34

Throttle/Shift Remote Control and Cables …..............................….……...……...……...……...………......... 35

Seawater Pickup Connection …..............…...……....................…...……...……...……...……...……......... 35

Seacock Size Recommendation …..............…...…...........…............……...……...……...……...……......... 35

Sea Strainer Recommendation …..............…...…...........…..........…...…...……...……...……...……......... 35

Crankcase Oil Dipstick Relocation …..............…................................……...……...……...……...……....... 35

Engine Installation …............................…...……....................…...……...……...……...……...……......... 36

…..............…...……..................................……...……...……...……...………......... 3

…..................................................……...……...……...……...………......... 3

…...................…...…...……...…...................……...……...……...……...………........ 3

…..............….........……..……...……...……...……...………......... 4-6

…..............….......……...……...……...............…...……...……...……...………......... 8

…..............…...…....……...…..............……...……...……...……...………......... 8

….............…...……...........….……...……...……...….......………......... 8

…..............…...…….........……...…...............…...……...……...……...………......... 8-11

…..............…...…..........…...……...……............……...……...……...……...………........ 13

…................…...….....................……...……...……...……...………......... 14

…................…...…........................................……...……........................... 16

L510023-07

1

SECTION ...................................................................................................................……................................................ Page

Torque Specifi cations …........................…...……....................…...……...……...……...……...……......... 36

Preliminary Engine Alignment ….............…...…….....................…...……...……...……...……...……......... 36

Final Engine Alignment …......................…...…….....................…...................…...……...................... 37-39

Throttle/Shift Cables

Audio Alarm System …..............…..............…….....................…...……...……...……...……...……......... 43

Exhaust System Connection

Engine Harness Connection

Battery Connection …..............…..............……..........…............……...……...……...……...………......... 44

Master Engine Specifi cations ….......................……..............…...……...……...……...……...……........ 45-48

Delivery Preparation …..............…..............……......................…...……...……...……...……...……........ 49

Pre-Delivery Checklist

Pre-Delivery Procedure

INSTALLATION DRAWINGS:

EXHAUST SYSTEM INSTALLATION GUIDELINES ...................................................................................... 60

CAPTAIN’S CHOICE INSTALLATION DRAWINGS:

5.7L BOSCH / VELVET DRIVE 72 REDUCTION .......................................................................................... 61

5.7L BOSCH / HURTH 630 8° DOWN ANGLE

5.7L BOSCH / HURTH 630V

5.7L BOSCH / VELVET DRIVE 72 DIRECT DRIVE ...................................................................................... 64

6.0L W/4 IN. RISERS / HURTH 630 8° DOWN ANGLE ................................................................................. 65

8.1L / HURTH 630A 8° DOWN ANGLE

8.1L / VELVET DRIVE 72 DIRECT DRIVE

8.1L / VELVET DRIVE 72 REDUCTION ...................................................................................................... 68

CRUSADER XL SERIES INSTALLATION DRAWINGS:

350XL-HT WITH HURTH V-DRIVE GEAR .................................................................................................. 69

350XL-HT WITH VELVET DRIVE 5000V GEAR .....

350XL-HT WITH HURTH SERIES - 8° DOWN ANGLE ......

350XL-HT WITH VELVET DRIVE 72 SERIES V-DRIVE ............................................................

350XL-HT WITH VELVET DRIVE 72 SERIES REDUCTION .......................................................................... 73

350XL-HT WITH VELVET DRIVE 5000 SERIES - 8° DOWN ANGLE ............................................................. 74

Crusader Engines Distributors ….......…........................................…...……...……................................... 75

Appendix A Captain’s Choice and Xli Installation Drawings …........……...……...……...……...……......... A1-A40

Appendix B XL Series Installation Drawings …......................…...……...……...……...……...…............. B1-B30

…..............…..............……...............…...……...……...……...……...………....... 39-43

…....…..............…….........................……...……...……...……...………....... 44

….....................……..................…...……...……...……...……...………........ 44

…............…................……..................….......…...……...……...……...……......... 49

…............…........................................…...……...……...…..……...……......... 50-59

............................................................................................. 62

.................................................................................................................... 63

...................................................................................................... 66

...................................................................................................67

...................................................................................

.......................................................................

.........

.......... 72

.70

. 71

2

L510023-07

GENERAL INFORMATION

Notice to Installer

Throughout this manual, “Warnings” and “Cautions”
(accompanied by the International Hazard Symbol)
are used to alert the installer to special instructions
concerning a particular service or operation that may
be hazardous if performed incorrectly or carelessly.
Observe them carefully!

These “Safety Alerts” alone cannot eliminate the hazards
that they signal. Strict compliance to these special
instructions when performing the service, plus “common­sense” operation, are major accident prevention
measures.

WARNING

Hazards or unsafe practices which could result in
severe personal injury or death.

CAUTION

Hazards or unsafe practices which could result in
minor personal injury or product or property damage.

IMPORTANT: Indicates information or instructions
that are necessary for proper installation and/or

operation.

Experience gained over the past several years has
shown that marine engines fi tted with electronic fuel
injection (EFI) require carefully integrated fuel delivery
systems. More specifi cally, the fuel tank, fuel supply
and return lines, fuel fi lters and all their associated
valves and fi ttings must be considered an integral part
of any fuel injection engine package. This may require
changes in both fuel system components and/or layout
to assure compatibility and 100% customer satisfaction
with the latest EFI engines.

Any new or re-power application involving the
replacement of a non-EFI engine with an EFI engine
may require a new or modifi ed fuel delivery system,
from the tank to the engine, for proper operation. This
installation manual has been published by Crusader
Engines to aid installers when installing the products
described herein.

It is assumed that these personnel are familiar with the
installation procedures of similar products manufactured
and marketed by Crusader Engines. That they have
been trained in the recommended installation procedures
of these products which includes the use of mechanics’
common hand tools and any recommended tools from
other manufacturers.

We could not possibly know of and advise the marine
trade of all conceivable procedures by which an
installation might be performed and of the possible
hazards and/or results of each method. We have not
undertaken any such wide evaluation. Therefore,
anyone who uses an installation procedure and/or tool,
which is not recommended by the manufacturer, fi rst
must completely satisfy himself that neither his nor the
product’s safety will be endangered by the installation
procedure selected.

All information, illustrations and specifi cations contained
in this manual are based on the latest product
information available at the time of publication.

ENGINE MODELS

This manual gives installation guidelines for the following
engine models.

MP 5.0L / MP 5.7L

MP 6.0L

MP 8.1L STD

MP 8.1L HO

Carb. 5.7L

CRUSADER ACCESSORIES

Instrument panels, wiring harnesses, propeller shaft
couplers, etc. are available for this product. Contact
your Crusader Engines Distributor or Crusader Engines
Sales Department for a listing of these options. A list of
Distributors is provided at the end of this manual.

ENGINE INSTALLATION ACCESSORIES

Electric Fuel Solenoid Valve P/N 23532

Solenoid Valve Power Harness P/N 98452

Water Separating Fuel Filter Kit P/N RK080033

Check Engine Lamp / Alarm Kit P/N RK179008

Crusader Sync-N-Cruz Kit P/N RF152007

Master / Slave Wire Harness: P/N RA121072C

Adapter - Engine to Boat Harness see page 20

Boat to Engine Harness see page 21

INSTALLATION SUPPLIES

Marine Lubricant

Liquid Neoprene

Perfect Seal or equivalent

Loctite PST Pipe Sealant or equivalent

Mount Adjustment Tool - P/N 22165

INSTALLATION DRAWINGS

Installation drawings are at the back of this manual.
These and archive installation drawings, are also
available at crusaderengines.com

L510023-07

3

ENGINE AND TRANSMISSION
COMBINATIONS

Engine Rotation:

Engine rotation is indicated by the model number on the
engine serial number plate. Engine rotation is described
by fl ywheel rotation viewing from the rear of the engine
(transmission end) looking forward to the water pump
end. Refer to the Crusader Model Identifi cation/Advisory
information below.

CRUSADER MODEL IDENTIFICATION /
ADVISORY

MODEL 23 - 6 0 0 V - 0 1 SERIAL 670000

1st - 2nd Space: MANUFACTURING CODE

rd - 5th

3

Space: ENGINE CODE

810 = 8.1L (496 CID LH MPI) (GM)
811 = 8.1L (496 CID LH H.O. MPI) (GM)
600 = 6.0L (364 CID LH MPI) (GM)
570 = 5.7L (350 CID LH MPI) (GM)
571 = 5.7L (350 CID RH MPI) (GM)
572 = 5.7L (350 CID LH Carburetor) (GM)
573 = 5.7L (350 CID RH Carburetor) (GM)
500 = 5.0L (305 CID LH MPI) (GM)
501 = 5.0L (305 CID RH MPI) (GM)
502 = 5.0L (305 CID LH Carburetor) (GM)
503 = 5.0L (305 CID RH Carburetor) (GM)

*SERIAL NUMBER I.D.*

1st DIGIT INDICATES DECADE ENGINE WAS
MANUFACTURED ( 5 = 1990, 6 = 2000, 7 = 2010 )

nd

DIGIT INDICATES YEAR ENGINE WAS

2
MANUFACTURED.

th

Space: DRIVE CONFIGURATION

6
blank - Direct Drive
V - V-Drive

th - 8th

7

Space: SPECIFICATION CODE

Figure 1 Flywheel Showing LH Rotation

4

L510023-07

Figure 2 Engine Applications - Typical 8 Degree Down Angle Transmission

Figure 3 Engine Applications - Typical V-Drive Transmission

L510023-07

5

Figure 4 Engine Applications - Typical Remote V-Drive Transmission

TRANSMISSION ROTATION

Velvet Drive In-Line and V-Drive

Transmission gear ratio (in forward gear) is marked
on the transmission identifi cation plate. Transmission
output shaft rotation is indicated on a decal on the
transmission case.

IMPORTANT: Use of proper rotation propeller,
indicated by the output fl ange rotation decal, is
critical as operating the transmission in Reverse to
move the boat forward WILL CAUSE transmission
failure. The transmission MUST BE operated in
forward gear only to propel the boat forward.

PROP SHAFT

ROTATION

DECAL

F

N

R

POPPET

BALL

TOWARD

FLYWHEEL

FOR

FORWARD

Figure 6 Shift Lever Positions - Standard Velvet Drive

IDENTIFICATION

TAG

Figure 5 Standard Velvet Drive Identifi cation Plate and

Propshaft Rotation

6

L510023-07

Velvet Drive 5000 Series and Hurth
Transmissions

These transmissions are “Full Reversing” with an
8-degree, down-angle output fl ange. This allows a
standard (LH or CCW) rotation engine to be used
for both propeller shaft rotations. Shaft rotation is
determined by shift cable installation at the remote
control (Figures 7 and 8). Transmission gear ratio
and serial number is marked on the transmission
identifi cation plate.

LH

FORWARD

GEAR

FORWARD

GEAR

RH

RH PROP SHAFT ROTATION

LH PROP SHAFT ROTATION

VELVET DRIVE 5000

TRANSMISSIONS

Figure 7 Shift Lever Positions - Velvet Drive 5000

FORWARD

GEAR

FORWARD

GEAR

LHRH

LH PROP SHAFT ROTATION

RH PROP SHAFT ROTATION

HURTH

TRANSMISSIONS

Figure 8 Shift Lever Positions - Hurth

L510023-07

7

GEAR RATIO SELECTION

The propeller shaft speed is determined by engine
speed and transmission gear ratio. Fast boats operate
best with direct drive or small reductions. Heavier boats
respond best with larger ratios of gear reduction.

If shaft speeds are too high, a smaller than normal
propeller must be used resulting in poor performance.
Conversely, if shaft speeds are too low, a larger than
normal propeller must be used, again resulting in poor
performance.

ENGINE RPM CHART

Minimum
Model Full Load Maximum Preferred

MP 5.0L 4600 5000 4800

MP 5.7L 4800 5200 5000

MP 6.0L 4800 5300 5200

MP 8.1L STD 4400 4800 4600

MP 8.1L HO 4800 5200 5000

PROPELLER SHAFT / COUPLING

Installed angle of the engine should not exceed
maximum of 16 degrees from water line.

Propeller shaft diameter should be suffi cient size for the
type of application.

Coupling must be keyed to the propeller shaft. The key
should be a close fi t with keyway sides, but should not
touch the top of the keyway in the coupling hub. The
coupling should be a light press fi t on the shaft.

TRANSMISSION AND PROPELLER
ROTATION

For best all-around performance, it is recommended
that the engines be installed so that the propellers turn
outboard in dual engine applications.

NOTICE: Propeller rotation is not necessarily the same
as engine rotation.

PROPELLER SELECTION

IMPORTANT: Installed propeller must allow the
engine to run at its specifi ed, Preferred, wide-open­throttle RPM.

It is the responsibility of the boat manufacturer and/or
selling dealer to equip the boat with the correct propeller.
Specifi ed engine WOT RPM is listed in the “Master
Engine Specifi cations” found within this manual.

Because of many variables of boat designs, only
testing will determine the best propeller for a particular
application. A propeller should be selected that will allow
the engine to operate at or near the recommended WOT
operating range with a normal load. Refer to the engine
RPM chart, right, or the Master Engine Specifi cations
found in this manual.

In general, a 1 inch change in propeller pitch will result in
a 100 to 200 RPM change in engine speed.

IMPORTANT NOTICE:

the ECM-07 engine management system incorporate
an RPM “MAX Governor” in order to prevent the
engine from over-revving. Engine operation above the
Maximum RPM listed will appear normal, but will not
exceed the “MAX Governor” RPM (100 RPM above
the Maximum RPM specifi ed for an engine model).
Operation above the maximum RPM specifi ed for your
engine model is not recommended. If the engine is
operating above the maximum RPM, a higher pitched
propeller would be required to lower the engine
maximum RPM to the Preferred RPM specifi ed for your
engine model.

Minimum
Model Full Load Maximum Preferred

Carb. 5.7L 4800 5200 5000

Engines equipped with

CAUTION

Prolonged WOT operation will shorten the life of your
engine and could cause premature engine failure.
See Cruising RPM (Max) in the Master Engine
Specifi cations. Problems caused by WOT operation
are considered abuse and are not covered under the
Crusader Warranty.

8

L510023-07

Single Engine Velvet Drive In-Line Installation

- (1:1, 1.52:1, 2.57:1 or 2.91:1 Ratio)

The transmission output shaft rotation is the same as the
engine rotation. A LH (CCW) rotation engine requires a
LH propeller.

FRONT

LH OR CCW

ENGINE

ROTATION

FLYWHEEL

LH

Figure 9 Single Engine Velvet Drive in-Line Installation

- 1:1, 1.52:1, 2.57:1 or 2.91:1 Ratio

L510023-07

9

Single Engine Velvet Drive In-Line Installation

- (1.90:1 Ratio)

The transmission output shaft rotation is the opposite
of the engine rotation. A LH (CCW) rotation engine
requires a RH propeller.

FRONT

LH OR CCW

ENGINE

ROTATION

INTRODUCTION - 1

Single Engine V-Drive Installation

The transmission output shaft rotation is the opposite
of the engine rotation. A LH (CCW) rotation engine
requires a RH propeller.

INPUT
GEAR

ROTATION

OUTPUT
FLANGE

ROTATION

FLYWHEEL

LH OR CCW

ENGINE

ROTATION

FLYWHEEL

RH

Figure 10 Single Engine Velvet Drive in-Line Installation

- 1.90:1 Ratio

FRONT

RH

Figure 11 Single Engine V-Drive Installation

10

L510023-07

Dual Engine Velvet Drive 5000 and Hurth 630A
Installation

These “Full-Reversing” transmissions rotate equally in
either direction depending upon shift lever position and
desired propeller rotation.

Velvet Drive 5000 gear ratios include: 1.50:1, 2.00:1,

2.45:1 or 2.80:1.

Hurth 630A gear ratios include: 1.50:1, 2.00:1, 2.50:1 or

2.70:1.

Dual Engine Velvet Drive 5000 and Hurth 630V
V-Drive Installation

These “Full-Reversing” V-Drive transmissions rotate
equally in either direction depending upon shift lever
position and desired propeller rotation.

Velvet Drive 5000 V-Drive gear ratios include: 1.21:1,

1.51:1, 1.99:1 or 2.50:1.

Hurth 630V gear ratios include: 1.30:1, 1.55:1, 2.00:1 or

2.50:1.

FRONT

LH OR CCW

ENGINE

ROTATION

FRONT

LH OR CCW

ENGINE

ROTATION

FLYWHEEL FLYWHEEL

FLYWHEEL FLYWHEEL

LH OR CCW

ENGINE

ROTATION

LH OR CCW

ENGINE

ROTATION

FRONT FRONT

LH

Figure 12 Dual Engine Velvet Drive 5000 and Hurth

630H Installation

RH

L510023-07

LH

Figure 13 Dual Engine Velvet Drive 5000 and Hurth

630V V-Drive Installation

RH

11

BOAT CONSTRUCTION

Engine Bed

The engine bed should be a horizontal type and rigid
enough to maintain engine alignment at all times.
Distance between the starboard and port engine mounts
is 22 1/2 in. (57.15 cm). The engine bed should support
the four (4) engine mounts in such a manner so that a
minimum of 1/4 in. (0.64 cm) up and down adjustment
still exists on all the mounts after the fi nal engine
alignment has been performed. This is necessary to
allow for realigning the engine in the future.

Figure 14 Engine Bed

Use adequately sized bolts to attach the engine to the
stringers or mounting plates. It must be remembered
that all the force used to drive the boat through the water
is transferred to the hull through the engine bed. Make
sure there is adequate clearance between the underside
of the engine and the hull.

1/2" x 6" LAG SCREW

(MINIMUM LENGTH)

ADJUSTING

SLEEVE

STRINGER

Figure 15 Engine Mount Attachment

INSTALLATION REQUIREMENTS

Battery/Battery Cables

IMPORTANT: Boating industry standards (BIA,
ABYC, etc.), Federal standards and Coast Guard
regulations must be adhered to when installing the
battery. Be sure the battery cable installation meets
the pull test requirements and that the positive
battery terminal is properly insulated in accordance
with the regulations.

IMPORTANT: Engine electrical system is negative
(-) ground. It is recommended (required in some
states) that the battery be installed in an enclosed
case. Refer to the regulations in your area.

1. Select a battery that meets all of the following
specifi cations:

A. 12-volt marine type

B. Tapered post connections

C. Reserve capacity rating of at least 100

minutes

12

MINIMUM 12-VOLT BATTERY SIZE

All Engines 650 CCA 120 Ah

2. Select the proper size positive (+) and negative
(-) battery cables using the chart. Battery should
be located as close to the engine as possible.

3. In twin engine applications, it is recommended
that both engines be grounded together using a
cable of adequate gauge.

L510023-07

IMPORTANT: Terminals must be soldered to the
cable ends to ensure good electrical contact. Use
electrical grade (resin fl ux) solder only. Do not use
acid fl ux solder as it may cause corrosion and a
subsequent failure.

BATTERY CABLES

Cable Length Cable Gauge

Up to 3-1/2 ft. (1.1 m) 4 (19 mm2)

3-1/2 - 6 ft. (1.1 - 1.8 m) 2 (32 mm2)

6 - 7-1/2 ft. (1.8 - 2.3 m) 1 (40 mm2)

7-1/2 - 9-1/2 ft. (2.3 - 2.9 m) 0 (50 mm2)

9-1/2 - 12 ft. (2.9 - 3.7 m) 00 (62 mm2)

12 - 15 ft. (3.7 - 4.6 m) 000 (81 mm2)

15 - 19 ft. (4.6 - 5.8 m) 0000 (103 mm2)

INSTRUMENTATION

CAUTION

If a Crusader wiring harness is used, and a fused
accessory panel is to be installed (30 amp current
draw maximum), be sure to connect it as shown in
wiring diagram. Do not connect accessory panel at
any other location, as wires in wiring harness may not
be of suffi cient size to handle current load.

For ECM-07 equipped engines, instrumentation at
the dash is no longer driven by separate senders
on the engine. Instrumentation is now driven by the
engine control module (ECM-07) and is just another
function of the engine management system. As such,
programming or calibration of the ECM is critical for
proper instrumentation operation.

The 4 basic gauges which must be used with the engine
are:

• Tachometer

• Oil Pressure

• Water Temperature

• Voltmeter

If you experience erroneous instrumentation readings,
the most common reasons for this condition are:

(1) The boat is equipped with dual helm

instrumentation. Verify through your selling
distributor/dealer that the calibration in the ECM
is for dual helm instrumentation.

(2) Some instruments may still require instrument

specifi c senders to be installed on the engine.
Contact your selling distributor/dealer with your

instrument manufacturer’s name. You may need
to install an oil pressure and water temperature
sender on your engine and use a different engine
to boat harness adapter.

(3) Faulty wire connections at the instrument panel

and/or the old instruments are defective and need
to be replaced.

Refer to pages 20 and 25, for replacement boat
harnesses, adapter harnesses, and Sync-N-Cruz Speed
Control Harness + FWMurphy Instrument interface.

Crusader Engines are equipped with the ECM-07 engine
management system. This system outputs J1939 and
NEMA 2000 protocol messages that may be utilized by
various manufacturers of multifunction displays; such as,
FWMurphy’s CAN Bus instruments and PowerView and
HelmView, which provide expanded display capabilities.

Always check with the manufacturer of the
instrument you are considering, prior to purchase,
for compatibility. These multifunction digital displays

not only display typical engine data, such as oil pressure,
water temperature, tach, etc., but also provide expanded
displays for fuel consumption, ECM-07 diagnostic code
display, and much more.

When replacing or installing the main boat harness,
route the instrumentation wiring harness back to the
engine, making sure that the harness does not rub or get
pinched. If an extension harness is required, be sure to
secure the connection properly. Fasten harness to the
boat at least every 18 in. (45.72 cm) using appropriate
fasteners.

TWIN ENGINE SYNCHRONIZATION AND
SPEED CONTROL (OPTIONAL)

MY 2007 and newer multi-port fuel injected engines
are equipped with the ECM-07 engine management
system. This new system has allowed more features to
be available than ever before. One of signifi cance is the
ability to provide twin engine synchronization and speed
control without having to add expensive aftermarket
equipment. This feature is available on all ECM-07
multi-port fuel injected engine models. Refer to the
diagram on page 23 for the accessory harnesses and
keypad required to enable this feature.

REQUIREMENTS:

• Master/Slave Harness - RA121072C

• Sync-N-Cruz Kit - RF152007

NOTE: The Sync-N-Cruz Contorl Panel and harnesses
are available as separate items for unique installation
requirements. Refer to page 23 for harness options.

IMPORTANT: Sync-N-Cruz harness must be connected
to the Master engine.

Refer to the Crusader Owners Manual for operating
instructions for the Sync-N-Cruz system.

L510023-07

13

When installing the Sync-N-Cruz harness, route the
harness back to the Master engine, making sure that the
harness does not rub or get pinched. If an extension
harness is required, be sure to secure the connection
properly. Fasten harness to the boat at least every 18
in. (45.72 cm) using appropriate fasteners.

MASTER/SLAVE WIRING CONNECTION

This connection allows the CAN Bus data lines to be
joined together for dual engine applications.

The benefi ts of a Master/Slave connection are:

• Allows for twin engine Sync-N-Cruz operation.

• Electronic Engine Monitor systems installed at
the helm area may display engine data for both
engines.

IMPORTANT: In dual engine applications, the
master/slave wiring harness is used to connect the
engines together. One end of this harness has one
more wire in it than the other end. The end with the
extra wire is plugged into the Slave engine harness.
This extra wire is then attached to the ground stud
on the Slave engine.

ENGINE WARNING KIT (OPTIONAL)

An engine warning kit, RK179008, is available. This kit
contains a Check Engine Lamp and Warning Buzzer.
It is recommended that the boat be equipped with a
Check Engine Lamp (Malfunction Indicator Lamp - MIL)
and buzzer. These devices warn the boat operator of
potential engine problems.

making sure that the wires do not rub or get pinched.
Fasten wire(s) to the boat at least every 18 in. (45.72
cm) using appropriate fasteners.

• Using existing Round 10-pin BOAT

harness connector

Pin-4 = Buzzer
Pin-9 - MIL or Check Engine Lamp

Verify that connections exist at the helm. If not,

two new wires will be required between the helm
and pins 4 (MIL) and 6 (Buzzer) of the Engine
harness 8-pin Deutsch connector.

• Using the Crusader boat harness (P/N

• Using existing Rectangular 8-pin BOAT

harness connector

* Requires two additional wires for the MIL and

Buzzer. The MIL is connected to pin-6 and
the Buzzer is connected to pin-4 of the Engine
harness, 8-Pin, Deutsch connector.

RA121092/RA121092A), the MIL is wired at
the helm to the Green/Yellow wire and the
Buzzer is wired to the Tan/Black wire.

• If previously equipped with the Optional

Crusader Warning Light Cluster P/N 23505:

Figure 16 Optional Warning Light / Alarm - Crusader

Part No. RK179008

Some boat wiring may already support these devices
and/or they may already be installed at the helm.
Ensure that the new connections match up to the
existing boat wiring and warning devices.

Ensure the light and buzzer wires are in the existing boat
harness, otherwise new wires will have to be run from
the helm to the engine. Use 18 ga minimum wire size,

OIL

PRESS

WATER

TEMP

Figure 17 Optional Warning Light Cluster - Crusader

Part No. 23505

The Check Engine lamp, of the cluster, and

the existing Buzzer may be used with ECM-07
engine models.

(1) At each engine, locate the Warning Cluster

Harness, 8-pin connector. The wires at Pin-A
(Orange/Tan wire, Check Engine Lamp) and
Pin-B (Tan/Red wire, Buzzer) will be the only
wires used. Cut the 8-Pin connector off of the
harness and tape back the wires not used.

CHK

ENGINE

TRANS

TEMP

14

L510023-07

(2) Splice pin-A (Orange/Tan) to pin-6 of the

respective engine 8-pin Deutsch connector and
pin-B (Tan/Red) to pin-4 of the engine 8-pin
connector. Only, the Check Engine Lamp
and alarm buzzer of the warning cluster will be
functional. Refer to the wiring diagram below

for connection/splice options for the MIL and
Buzzer.

Dash Side

CHK

TEMP

TRANS

ENGINE

OIL

TEMP

WATER

PRESS

23505

Display

98387/98388

HARNESS

CUT 8-PIN

CONNECTOR

OFF HARNESS

Warning Cluster

Existing Harness and

Harness

Existing Boat

CHK

ENGINE

OIL

PRESS

23505

Display

CUT 8-PIN

CONNECTOR

OFF HARNESS

TEMP

TRANS

TEMP

WATER

98387/98388

HARNESS

Warning Cluster

Existing Harness and

Harness

Existing Boat

PIN-B TAN/RED

SPLICE TO

TAN/BLACK IN

RA121093

PIN-A ORANGE/TAN

SPLICE TO

GREEN/YELLOW

IN RA121093

ENGINE

HARNESS

PORT/

SLAVE

ENGINE

GND

RA121093

Part Number -

Part Number -

Master / Slave

Engine Harness

L510023-07

RA121072C

PIN-B TAN/RED

SPLICE TO

TAN/BLACK IN

RA121093

PIN-A ORANGE/TAN

SPLICE TO

GREEN/YELLOW

IN RA121093

ENGINE

HARNESS

Engine Side

RA121093

Part Number -

STARBOARD/

MASTER

ENGINE

15

ELECTRICAL SYSTEM PRECAUTIONS

To avoid damage to the electronic fuel injection (EFI)
system, the following precautions must be observed
when adding additional electric accessories.

• DO NOT reverse battery leads.

• DO NOT splice wires into engine electrical harness.

• DO NOT puncture engine wires for testing
(probing).

• DO NOT attempt engine diagnostics without the
proper service tools.

• DO NOT attach any accessory wiring to the ECM
ground location.

TWIN ENGINE

MASTER/SLAVE

CONNECTOR

SLAVE ENGINE

GROUND TERMINAL

Figure 18 ECM Slave Ground Terminal

TO SLAVE ENGINE

GROUND STUD

TO SLAVE

ENGINE

TO MASTER

ENGINE

2-PIN BOAT

HARNESS

CONNECTOR

FUEL TANK

SOLENOID

CONNECTOR

8-PIN BOAT

HARNESS

CONNECTOR

SPEED CONTROL/

CAN BUS

CONNECTOR

Figure 20 Electrical System Connectors

INSTALLATION NOTE: When installing the

Optional Crusader Sync-N-Cruz system, the speed
control harness (RA121091/RA121091A) MUST be
connected to the Master engine, 20-Pin Speed Control/
CAN Bus Connector and the master/slave harness
(RA121072C) must connect the Master and Slave
engines together. Ensure that the Slave side of the
harness is grounded to the Slave engine.

Figure 19 Master / Slave Wire Harness

16

L510023-07

NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.

A

NOTE
THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS.

: POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM

2-PIN WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS
NUMBER NAME WIRE COLOR

A

1. VBAT RED/PURPLE

2. GROUND BLACK

8-PIN WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS
NUMBER NAME WIRE COLOR

1. (OPEN) CAVITY PLUG

2. TACHOMETER GRAY

3. COOLANT TEMP TAN

4. BUZZER TAN/BLACK

5. IGNITION PURPLE

6. MIL GREEN/YELLOW

7. STARTER YELLOW/RED

8. OIL PRESSURE DARK BLUE

TWIN ENGINE

MASTER/SLAVE

CONNECTOR

ENGINE

HARNESS

2-PIN BOAT

HARNESS

CONNECTOR

FUEL TANK

SOLENOID

CONNECTOR

8-PIN BOAT

HARNESS

CONNECTOR

NOTE: The ‘MIL’ or Malfunction Indicator Lamp may be labeled the “Check
Engine Lamp” on the instrument panel. Check the boat owners manual for
exact labelling.

SPEED CONTROL/

CAN BUS

CONNECTOR

Figure 20A - Electrical System Connectors

INSTALLATION NOTE: When installing the Optional Crusader Sync-N-Cruz system, the speed control harness

(RA121091/RA121091A) MUST be connected to the Master engine, 20-Pin Speed Control/CAN Bus Connector and
the Master/Slave harness (RA121072C) must connect the Master and Slave engines together. Ensure that the Slave
side of the harness is grounded to the Slave engine.

L510023-07

17

CRUSADER CLASSIC 5.7L CARBURETOR

- ELECTRICAL SYSTEM PRECAUTIONS

To avoid damage to the electrical system, the following
precautions must be observed when adding additional
electric accessories.

• DO NOT reverse battery leads.

• DO NOT splice wires into engine electrical
harness.

• DO NOT puncture engine wires for testing
(probing).

• DO NOT attempt engine diagnostics without the
proper service tools.

• DO NOT attach any accessory wiring to the ECM
ground location.

CRUSADER CLASSIC ACCESSORIES

Instrument panels, wiring harnesses, propeller shaft
couplers, etc. are available for this product. Contact
your Crusader Engines Distributor or Crusader Engines
Sales Department for a listing of these options. A list of
Distributors is provided at the end of this manual.

ENGINE INSTALLATION ACCESSORIES

Electric Fuel Solenoid Valve P/N 23532

Solenoid Valve Power Harness P/N 98452

Water Separating Fuel Filter Kit P/N RK080033

Adapter - Engine to Boat Harness 98218
10-Pin to 8-Pin Male

Adapter - Engine to Boat Harness R121073
10-Pin to 8-Pin Female

NOTE: Twin engine Sync-N-Cruz, multifuction
displays, and CAN-Bus instrumentation options
are not available with the Crusader Classic series
engines.

ENGINE

WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS
NUMBER NAME WIRE COLOR

1. GROUND BLACK

2. TACHOMETER GRAY

3. WATER TEMPERATURE TAN

4. N/C

5. IGNITION PURPLE

6. BATTERY RED

7. STARTER YELLOW/RED

8. OIL PRESSURE LT. BLUE

9. N/C

10. N/C

NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.

A

NOTE
FROM THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS.

: POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN

HARNESS
ADAPTER

2

10

3

4

5

1

8

9

7

6

A

IMPORTANT: Your engine is designed to work with the standard electronics installed in your boat. If you add other

electrical components or accessories, you could change how the overall electrical system functions. Before adding
electrical equipment, consult your dealer. If you don’t, your engine may not perform properly.

CAUTION

Add-on equipment may adversely affect the alternator output or overload the electrical system. Any damage caused
as a result will not be covered by, and may void, your warranty.

18

L510023-07

ALT E R NAT OR

-

+

BATTER Y

BAT

STARTER

RED-

S

14g

DIS T R IB UT O R

(MALLO R Y )

I

a

GRD

SEN

EXC

BAT

RED - 6 ga

GREEN

BROWN

RED

BLACK 6 ga

RED/WHITE 16 ga

PURPLE/WHITE 16 ga

YELLOW 12 ga

RED

100A

LITTLE

FUSE

RED - 6 ga

FROM

PIN 1

6ga

Starter
Relay

BLACK 12 ga

FROM PIN 5

-+
IGNIT ION
COIL

RE

D

87

85

RED 16 ga

12 in. long

60A
Circuit
Breaker

RED/WH

3086

87A

TE

I

ga

12

YEL/RED

12 ga

NotUs ed

Ballast
Resistor

RED/WHITE

GRAY

WATER
TEMP
SENSOR

OIL
PRESS URE
SENSOR

TRANSMISSION
NEUT R AL
SAFETY
SWITCH

To - E XC
Alternator

PURPLE/WHITE

TAN

14ga

10ga 125 C

LT. BLUE 14ga

YEL/RED

12 ga

16ga

PURPLE/

WHITE

16 ga

14ga

10-PIN

ENGINE

HARNE S S

Water
Temp

3

B atte ry

6

Oil
Pressure

8

Starter

7

Tachometer

2

Ignition

5

5A
Fuse

DARK

GREEN/

YELLOW

14 ga

BLACK 14 ga

+-

ELECTRIC

FUEL

PUMP

Figure 20B Typical Engine Wiring w/Mallory Ignition - Crusader Classic 5.7L Carburetor

FROM

PIN 1

BLACK 14 ga

FROM

PIN 1

Low
Oil P res sure
Switch

E NG INE WAR N IN G CIR CU IT

-+

CARBURETOR

ELECTRIC

CHOKE

MOD U L E

RED 14 ga

LT. Green 14ga

Water
Temperature
Switch

PURPLE/WHITE 14 ga

Oil P res sure
Fuel Pump
Interlock
Switch

To ­Carburetor
Choke

To - Elec.
Fuel Pump

Pigtail connector

near 10-Pin connector

14 ga

E

URPLE/WHIT
P

To ­Starter
Relay

BLACK

125 C

GROUND

ENGINE BLOCK

10ga

Ground

1

L510023-07

19

10-Pin

Round Molded

W/VDO Sensor leads

10-Pin

Round Molded

8-Pin (F)

Dash Side

8-Pin (M)

14-Pin

Merc Style

Part Number -

Boat Adapter Harnesses

20

RA121093A

Part Number -

RA121093

L510023-07

RA121094

Part Number -

Part Number -

Engine Side

RA121094A

Part Number -

RA121098

# 22141

Crusader Instrument Panel

Dash Side

RK179008 -

(Requires 2 kits -

Lamp and Alarm Buzzer

Check Engine Lamp (MIL) Kit -

one for each engine.)

Part Number -

Replacement Boat Harnesses

(Requires 2 harnesses - one for each engine.)

All Boat Applications

BAT / Ground / Starter / Ignition

Oil Pressure/Coolant Temp Gauges/Buzzer

RA121092 - 25 FT, Unterminated

RA121092A - 45 FT, Unterminated

RA121092B- 25 FT, Terminated 8-Pin Connector

RA121092C - 25 FT, W/VDO Sender take-outs

Engine Boat Harnesses and Accessories

RA121072C

Part Number -

Master / Slave

Engine Harness

PORT/

SLAVE

ENGINE

GND

STARBOARD/

MASTER

ENGINE

NOTE: The above illustration represents a typical twin engine installation using Crusader harnesses and accessories.

Engine Side

L510023-07

21

Crusader supplied Boat Extension Harnesses

A

RA121092 = 25 ft

RA121092A = 45 ft

***Extension harnesses are used to connect engine

wiring to the helm.

Spliced at Helm by Installer

RED

Battery

(Panel

Power)

Ground

(Panel)

Deutsch 2-Way

Connector

P/N - DTP04-2P

GRY

2

TACH

TAN

345 6 7 812

Coolant

Temperature

Sender

TAN/
BLK

PPL

Buzzer Ignition

Feed

GRN/
YEL

Malfunction

Indicator

Lamp (MIL)

Deutsch 8-Way Connector

P/N - DT04-8PA

YEL/
RED

Starter

Circuit

BLUBLK

Oil

Pressure

Sender

22

RA121092_092

9-28-06

L510023-07

4

5

6

1

2

3

AB

SLAVE

+ Battery

- Ground

Dash Side

4

5

6

AB

1

2

Murphy PowerView

3

+ Battery

MASTER

- Ground

Cruise

Sync

+ Battery

Speed

(+)/Res

Set

Speed

ON

Syn/Cru

- Ground

(-)

Cancel

OFF

RA152007

Part Number -

OPTIONAL -

Murphy Supplied

Equipment

See your Distributor/

Dealer for the kit

Murphy CAN

you require.

Bus Instruments

OR

Murphy HelmView

Murphy CAN

Bus Instruments

Part Number -

RA121091 - 25 FT, Engine to Panel

RA121091A - 45 FT, Engine to Panel

Engine Speed Control / CAN-Bus Harnesses

PORT/

SLAVE

ENGINE

GND

RA121072C

L510023-07

Part Number -

Engine Harness

Master / Slave

Includes:

RPM Cruise Only

Twin Engine Synchronization

CAN BUS Displays

Crusader

Harness - RA121091 - 25 FT, Engine to Panel

Control Panel - RA152007

Crusader Sync-N-Cruz Kit - RF152007

NOTE: The above illustration represents a typical twin engine installation using

Crusader and Murphy harnesses. Original boat harnesses may be used with the

STARBOARD/

MASTER

ENGINE

Engine Side

appropriate adapter and FWMurphy equipment may be used without the use of

the Crusader Speed Control/CAN Bus harness.

23

Sync/Cruise Switch Panel (RA152007)

RED/
YEL

LT
BLU/
BLK

ORN

BRN

5K

Sync

LED

Resistor

Sync/
Cruise

OFF CANCEL (-)

BLK BLK

Cruise

LED

Circuit

Board

SETON

Speed Speed

BLK

PPLPPL

(+) /
Resume

PPL

RED/
YEL

Cruise

(Ground)

Sync
LED

(Ground)

ORN

Request

Cruise

BRN

Sync

Request

ORN/
BLU

Speed

Set/

Cancel

LT
BLU/
BLK

LED

Deutsch 12-Way Connector

P/N - DT06-12S

Note: Panel 12-Way connector plugs directly into the following
Crusader supplied Boat Speed Control Harnesses:
RA121091
RA121091A

***See the following pages for schematics of these harnesses.

ORN/
GRN

910121138

Speed
Increment/
Decrement

To

Ground

From

Ignition

RA152007

9-28-06

24

L510023-07

Crusader supplied Boat Speed Control Harnesses

A

RA121091 = 25 ft

RA121091A = 45 ft

Deutsch 3-Way

Connector

P/N - DT06-3S

CAN 1

BUS

(+)

AB

BLK/
WHT

Twisted

WHT

CAN 1

BUS

(-)

Deutsch 12-Way

Connector

P/N - DT04-12PA

ORN/
LT
BLU

Speed

Set/

Cancel

Cruise

Request

11 10 9 8 12 3

ORN

Speed
Increment/
Decrement

ORN/
GRN

Cruise

(Ground)

RED/
YEL

LED

Request

BRN

Sync

(Ground)

LT
BLU/
BLK

Sync

LED

16 17 8 9 10 11 18 19

CAN 1

BUS

(+)

CAN 1

BUS

(-)

Cruise

Request

Speed

Set/

Cancel

Speed
Increment/
Decrement

Deutsch 20-Way Connector

P/N - HDP26-18-20SN

L510023-07

Cruise

LED

(Ground)

Sync

Request

Sync

LED

(Ground)

RA121091_091

9-28-06

25

ENGINE COMPARTMENT VENTILATION

USCG & ABYC Standards

United States Coast Guard regulations (33 CFR Section
183, subpart J & K) must be adhered to in any fuel and
ventilation system installation. In addition, we strongly
suggest that ABYC’s recommendations regarding fuel
systems and engine room ventilation be followed.

Care must be exercised in the design and construction
of the engine compartment. Hatch openings must be
located so that any rain water, which may leak through
the seams, is directed away from the engine. If water
enters the fl ame arrestor, it can enter the engine and
cause serious damage to internal engine parts.

IMPORTANT: Crusader Engines will not honor any
warranty claim for engine damage as a result of
water entry.

Over the past several years, engine compartments have
been made smaller and insulated to be quieter. This
trend, while resulting in quieter boats, has resulted in
higher engine compartment temperatures. It is important
that attention be given to the air temperatures inside
the engine compartment while running and for a period
of time after the engine is shut off. This period of time
after shutting off the engines is critical as temperatures
normally rise (heat soak) and can lead to fuel vapor lock
causing the engine startability problems.

Engine compartment must be designed to provide a
suffi cient volume of air for engine breathing, and must
vent off any fumes in engine compartment. It should
also be designed to allow heated air to escape and
maintain low temperatures during engine operation.
Cool air should enter the engine compartment as low as
possible and heated air should be vented from as high a
point as possible.

IMPORTANT: The size of ventilation opening must
be increased if any auxiliary equipment, such as
generators, is located in the engine compartment.

ENGINE AIR REQUIREMENTS

AT WIDE-OPEN-THROTTLE

Model Volume

MP 5.0L 670 ft3/min (0.320 m3/sec)

MP 5.7L 670 ft3/min (0.320 m3/sec)

MP 6.0L 670 ft3/min (0.320 m3/sec)

MP 8.1L STD 697 ft3/min (0.329 m3/sec)

MP 8.1L HO 697 ft3/min (0.329 m3/sec)

Air requirements listed are for single engine and
must be doubled for dual engine installations.

The pressure differential (outside engine compartment
versus inside engine compartment) should not exceed
2 in. (51 mm) of water (measured with a manometer) at
wide open throttle.

Engine Compartment & Fuel Temperature Testing
capable of operation throughout an ambient (air
temperature) range from 20° to 150°F (-7° to 65°C)
without failure. Crusader EFI and associated
components meet this standard.

Because electronic fuel injection systems require
higher fuel delivery pressures and higher volumes, fuel
temperatures become an issue. Engine compartment
temperatures have been measured in excess of 200°F
(82°C). High fuel temperatures may lead to excessive
vapor in the fuel line, particularly when gasoline
containing alcohol and the newer “reformulated” blends
are used. A maximum fuel temperature at the fuel
pump inlet of 105°F (40°C) and an ambient engine room
temperature of 150°F (65°C) must be adhered to.

To test for ambient air and fuel inlet temperature
compliance, proceed as follows:

The boat being tested should be a standard production
boat. The temperature meter used must be of a type
which can be read with the engine compartment closed.
The engine compartment is to remain closed and no air
is to be forced into the engine compartment during the
test. The bilge blower should not be running.

A. Install thermal couples 1 in. (25 mm) above each

fl ame arrestor for air temperature measurement.

B. Tee another thermal couple into the fuel line(s)

at the fuel pump inlet for measuring fuel
temperature.

C. Operate the engine(s) until engine and bilge

temperatures are stabilized. This usually
occurs when operating the engine under cruise
conditions for a minimum of one hour.

D. Shut engine(s) off and monitor temperatures

for an additional hour. Air temperature should
not exceed 150°F (65°C) and fuel temperature
should not exceed 105°F (40°C) at any time,
either during engine operation or engine off (hot
soak).

E. After the one hour hot soak test, start the

engine and let it idle (in neutral) for 20 minutes.
Continue to record temperatures for another 20
minutes.

If temperature limits are exceeded at any time during
this test, it is necessary to reevaluate the fuel system
and/or bilge ventilation and take appropriate measures
to maintain temperatures at or below the specifi ed limits
at all times.

26

L510023-07

FUEL SUPPLY AND RETURN
CONNECTIONS

USCG & ABYC Standards

United States Coast Guard regulations (33 CFR Section
183, subpart J & K) must be adhered to in any fuel and
ventilation system installation. In addition, we strongly
suggest that ABYC’s recommendations regarding fuel
systems and engine room ventilation be followed.

CAUTION

Using Loctite Pipe Sealant with Tefl on, lightly coat all
threads of the fuel fi ttings used at the tank, fuel fi lter,
fuel pumps, etc. DO NOT use Tefl on tape.

A fl exible fuel line must be used to connect fuel line
to and from the engine to absorb defl ection when the
engine is running. The accompanying drawing illustrates
the typical location on the engine for connection of fuel
supply and return lines. Remove shipping plugs and
connect fuel lines to the locations shown.

1. Fuel pickup should be at least 1 in. (25 mm) from
the bottom of the fuel tank to prevent picking up
impurities.

2. Dual installations; it is best to use a fuel pickup
and supply line for each engine. If a single
pickup and line is used, fi ttings and line must

not be smaller than 1/2 in. (13 mm) I.D.

3. Fuel tanks must have at least 1/2 in. (13 mm)
shut-off valves and fi ttings on the fuel supply line
and 3/8 in. (10 mm) shut-off valves and fi ttings
on the fuel return line.

4. There must be free fl ow into the top of the tank
for the return fuel line. There must not be a “dip
tube” extending into the tank.

5. On installations requiring long lines or numerous
fi ttings, larger size lines (than previously
specifi ed) should be used.

6. Fuel line should be installed free of stress,
and fi rmly secured to prevent vibration and/or
chafi ng.

7. Sharp bends in fuel lines should be avoided.

8. A fl exible fuel line must be used to connect fuel
line to the engine fuel pump to absorb defl ection
when engine is running.

9. Route all fuel lines as low in the bilge as
possible to take advantage of the cooler ambient
temperatures found there.

FUEL TANK

VENT

FUEL TANK

PICK UP

"NOT" ACCEPTABLE

FUEL TANK FILL

ANTI-SIPHON

VALVE OR SOLENOID

FUEL FEED LINE

FUEL RETURN

LINE

WATER
SEPARATING
FUEL FILTER

FUEL

CONTROL

CELL

ACCEPTABLE

LOW-PRESSURE

FUEL PUMP

RETURN FUEL LINE TO FUEL TANK CONNECTION

Figure 21 Engine and Fuel Line Installation

L510023-07

27

FUEL INLET RESTRICTION

The maximum allowable inlet restriction at the electric
fuel pump inlet is 2 in. Hg (6.75 kPa) at 40 GPH (151
LPH) fl ow (typical idle fl ow rate). To test this, tee a
digital vacuum gauge into the fuel supply line at the
inlet to the low pressure fuel pump and read the gauge
at engine idle. If fuel inlet restriction exceeds the
maximum, the following is recommended:

A. Use supply side fuel lines including valves

and fi ttings with at least 1/2 in. (13 mm) I.D.

B. DO NOT install any additional fuel fi lters

between the fuel tank and the fuel pump inlet.

C. Avoid using crossover valves unless

absolutely necessary.

D. If an anti-siphon valve(s) is required, it is

recommended to use an electric solenoid
shut-off valve.

TEE FITTING

FUEL INLET

i

n

H

g

O

N

O

FF

Z

E

R

O

S

T
O

R

E

H

O

L

D

M

E

M

O

R

Y

U

N

I

T
S

L

O

C

DI

G

I
T

A

L

-

M

A

N
OM

E

T

E

R

VACUUM GAUGE

Figure 22 Checking Fuel Inlet Restriction

FUEL LINES

IMPORTANT: Current or proposed legislation may
require the use of low permeation fuel lines when
re-powering. This type fuel line will be marked with
the ‘Type A1-15’ designation. Check your local and
state regulations regarding the required use of this
type of fuel line.

IMPORTANT: Return fuel must fl ow back to the tank
from which it was drawn to prevent over-fi lling and
fuel spills through the vent system.

IMPORTANT: Prior to engine installation, fuel lines
should be inspected for compatibility with ethanol
blended fuel.

Replacement fuel line should be USCG Approved,
Marine Grade fuel line for use with ethanol blended
fuels.

Recommended minimum size fuel line:

• 1/2” (13 mm) I.D. supply side

• 3/8” (10 mm) I.D. return side. (If required.)

Fuel lines should be secured per ABYC
recommendations. In addition, the following steps
should be followed to minimize fuel temperature:

A. Route all fuel lines as low in the bilge as

possible to take advantage of the cooler ambient
temperatures found there.

B. Keep the use of brass fuel elbows and fi ttings

to an absolute minimum. Brass is a good
conductor of heat. Tests have shown that fuel
may begin to vaporize when passing through
a 90 degree brass elbow at only 85°F (29°C)
ambient temperature.

C. Maintain adequate engine compartment

ventilation.

IMPORTANT: The electric fuel pump on the engine
has been designed to function with a fuel/water
separator, with 10 micron fi lter capability and a
minimum of 90 gallons per hour fl ow rate, between
the pump and fuel source. Crusader DOES NOT
recommend the use of any additional fi lters installed
by the OEM or boat dealer. The use of additional
fi lters which do not meet the requirements stated
above, can cause one or more of the following:

• Fuel Vapor Locking

• Diffi cult Warm-Starting

• Poor Drivability

• Piston Detonation Due to Lean Fuel Mixture

FUEL SYSTEM PRESSURE CHECK

Connect a fuel pressure tester to the test valve on the
fuel rail. Start and run the engine at idle and note the
fuel pressure reading. Verify reading meets or exceeds
minimum pressure (if shown) listed in the following chart.

Minimum WOT
Engine Pressure Pressure

MP 5.0L Master Specs. Master Specs.

MP 5.7L Master Specs. Master Specs.

MP 6.0L Master Specs. Master Specs.

MP 8.1L STD Master Specs. Master Specs.

MP 8.1L HO Master Specs. Master Specs.

Carb. 5.7L Master Specs. Master Specs.

IMPORTANT: Fuel pressure MUST be taken at wide­open-throttle conditions in order to ensure that the
correct fuel pressure is present at all times.

See MASTER SPECIFICATIONS at the end of this
manual for specifi cations not shown on the chart.

28

L510023-07

GASOLINE REQUIREMENTS

GASOLINE CONTAINING ALCOHOL

CAUTION

Fire and Explosion Hazard - Gasoline is extremely

fl ammable and highly explosive, and , if ignited,
can cause serious bodily injury or death. Careful
inspection of the entire fuel system including, but
not limited to, fuel tanks, fuel lines, fuel fi lters and
all fi ttings is mandatory, especially after periods
of storage. Replace any component that shows
signs of leakage, corrosion, deterioration, swelling,
hardening or softening.

WARRANTY NOTICE: Damage caused to the engine
through the use of improper gasoline, low-quality or
gasoline with an octane rating below the minimum
requirements listed below, is considered misuse of the
engine. Such damage is not covered by the Crusader
Marine Engines warranty.

The ignition timing set by the factory requires the use
of a high-quality lead-free regular gasoline with the
following octane specifi cation.

Pump Octane Number (R+M/2) (PUMP) - 87

The implementation of ethanol-based fuel is spreading
rapidly throughout the United States. As such, Crusader
Engines provides the following information regarding the
use of this fuel.

This information addresses the use of ethanol fuels in
CRUSADER ENGINES ONLY. It does not address the
use of ethanol fuels in vessel related components such
as boat gas tanks, boat fuel lines, etc.

Ethanol blended fuel rated E10 or less is acceptable
to use. Fuels rated higher than E10 SHOULD NOT
BE USED. Ethanol fuels rated higher than E10 could
potentially damage the engine and/or present an
unsafe boating condition. Damage to the engine
resulting from the use of ethanol fuel rated higher
than E10 IS NOT covered by the warranty.

CAUTION

Do Not use any gasoline that contains
METHANOL. This fuel is very corrosive and will
create unsafe operating conditions. Serious
damage will result from the continued use of fuel
containing METHANOL. Any resulting engine
damage will not be covered by the warranty.

UNLEADED

REGULAR

E10

$

MINIMUM OCTANE RATING

R + M/2 METHOD

87

UNLEADED

87

E10

Figure 23 Fuel Requirements

NOTICE: Most Crusader Fuel Injected engines are
calibrated to operate on 87 octane fuel and maximum
performance is obtained when using this fuel. Some
applications may require a higher octane fuel. These
particular applications will be noted.

If a slight pinging is heard during acceleration and the
proper octane fuel is being used, it is considered normal.
If a constant, heavy knock occurs, the engine should
be evaluated by a Crusader Marine Engines service
technician.

If ethanol blended fuel rated E10 or less is used, or
if the presence of alcohol is uncertain, more frequent
inspections and service of the complete fuel system are
required. Any sign of fuel leakage or deterioration must
be repaired immediately before further engine operation.

It is important to note that ethanol blended fuel will act
as a solvent and will attract and hold moisture. Without

proper fuel stabilization and fuel fi ltration, ethanol
blended fuel may cause the following:

• Excessive moisture (water) may cause lean
operation to include hard starting and operating
diffi culties such as, vapor lock, low speed
stalling, and shortened fuel shelf life.

• Acting as a solvent, ethanol blended fuel may
cause gum, sediment, sludge, and other particles
to be loosened and carried through the fuel
system to the engine.

Fuel system or engine damage caused by
contamination from water, foreign particles, sludge,
or gums entering or forming in the fuel system is not
covered by the Crusader Limited Warranty.

FUEL STABILIZER RECOMMENDATIONS
FOR ETHANOL BLEND FUEL

The use of a commercially available fuel stabilizer, such
as STA-BIL®, is recommended when storing ethanol­blended fuel for more than 2 weeks.

L510023-07

29

FUEL FILTER RECOMMENDATIONS FOR
ETHANOL BLEND FUEL

Because ethanol will act as a solvent and will attract
and hold moisture, Crusader Engines has removed the
Primary Fuel Filter or Fuel Pre-Filter and in its place a
fi tting will be provided for connection to a spin-on type
fuel/water separator.

A spin-on type fuel/water separator fi lter, of 10 micron
fi ltering capability with a minimum rating of 90 gallons
per hour is required between the low pressure fuel pump
and the fuel source. Crusader Engines recommends the
use of Crusader part number RA080033. This is a 3­piece, RACOR, fuel/water separator. This unit allows for
the easy draining of water and contaminate inspection
between service intervals, without the need to replace
the fi lter element during an inspection.

Crusader Engines recommends that the fuel/water
separator be mounted as low as possible, relative to the
fuel source, away from heat, such as exhaust runs, and
in an easily accessed and serviceable area.

Upon initial installation or service of the fuel/water
separator, the fi lter element should be pre-fi lled with
fresh fuel prior to mounting the element to the head.
Pre-fi lling the fi lter element, with fresh fuel, will reduce
the time required to prime/re-prime the fuel system after
a service interval.

Refer to the diagram below for height, width, depth,
and the minimum under bowl clearance for service
dimensions for the RA080033 fuel/water separator.

RA080033 - Fuel / Water Separator Assembly

R080033 - Fuel / Water Separator Replacement

Element

RK080033 - Fuel / Water Separator Kit, Includes

RA080033 Assembly plus 1/2” hose barb
fi ttings for Low Pressure Fuel Pump and
Separator Assembly.

FUEL

CONTROL

CELL

FUEL

SUPPLY

LINE

LOW-PRESSURE

FUEL PUMP

FUEL

RETURN

LINE

5.0/5.7L
ONLY

NOTE: Not all fuel systems use a return to tank fuel line.
Do not install a return to tank fuel line if your fuel system
was not originally equipped with one.

TO
FUEL
TAN K

FROM

FUEL

RA080033

TAN K

Height: 11.0 inches

Width: 4.2 inches

Depth: 4.5 inches

Figure 24 Fuel / Water Separator Installation

30

Under Bowl Clearance:

1.0 inch Minimum

L510023-07

EXHAUST SYSTEM

IMPORTANT: It is the responsibility of the boat
manufacturer, or the installing dealer, to properly
locate the engine and install the exhaust system.
Improper installation may allow water to enter the
exhaust manifolds and combustion chambers, and
severely damage the engine.

Damage caused by water entering the engine through
the exhaust system WILL NOT be covered by Crusader
Engines Warranty, unless the damage is the result of
defective part(s).

When designing and installing the exhaust system, it
is very important that the following points be taken into
consideration.

1. A water lift muffl er, or collector, mounted
close to the exhaust outlets - These
components hold hot water. Once the engine
is shut off, this sets up a “sauna” effect.
Condensation will form and enter the exhaust
manifolds and run into the cylinders in some
cases. Always try to install these components
as far away from the exhaust outlets as possible.

2. Not enough drop in the exhaust hose - The
most aggressive drop between the exhaust
outlet and the muffl er, or collector, will aid in
preventing condensation from forming and
working its way back into the exhaust manifold(s)
and elbow(s).

3. Engine Operation - You should never start
the engine just for the sake of warming it
when not being used. This does not get the
manifolds up to temperatures needed to burn off
condensation. This will get worse with colder
inlet water temperatures.

EXHAUST RISERS

To determine if exhaust risers are required, make the
following measurements. With the boat in the water and
maximum load onboard, make measurements “A” and
“B” (Figure 22). Subtract measurement “B” from “A.” If
the difference between the two measurements is less
than specifi ed on the drawing and chart below, it will be
necessary to add exhaust risers as required to correctly
position the exhaust elbow.

“A” minus “B” must be this
Engine Models distance or more

All Engines 12 in. (304.80 mm)

B

A -- FROM WATERLINE TO REFERENCE POINT
B -- FROM HIGHEST POINT ON EXHAUST ELBOW TO SAME REFERENCE POINT

Figure 25 Proper Exhaust Elbow Location

A

L510023-07

31

Exhaust Systems without Water-Lift Muffl ers

WARNING

Boating industry standards (BIA, ABYC, etc.), Federal
standards, and Coast Guard regulations must be
adhered to when designing and installing exhaust
systems.

1. System layout and construction must prevent
cooling system discharge water from fl owing
back into the engine, and also must prevent
seawater from entering the engine via the
exhaust system.

2. The exhaust hoses and pipes must not be higher
than the exhaust elbow outlets at any point.

3. The exhaust system (for routing exhaust to
outside of boat) must be located so that a
minimum of 1 in. per foot (83.31 mm per meter)
downward pitch exists in the exhaust hose or
pipe from the engine exhaust elbow to the outlet,
with a minimum drop of 4 in. (100 mm) overall
(this is an ABYC recommendation). The drop
must be constant so that a low spot does not
exist at any point in the exhaust hose or pipe.

4. Exhaust outlet(s) should be slightly above the
water line with the boat at rest in the water, and
a full load onboard. Exhaust outlet(s) must be
equipped with an internal shutter and/or exhaust
fl apper to prevent seawater from running back
into the exhaust system.

HOT SPOT

INCORRECT CORRECT

Figure 26 Exhaust Hose Connections

Figure 27 Typical Inline Muffl er Exhaust Layout

32

L510023-07

5. System must not cause excessive back
pressure. Back pressure MUST NOT exceed 4
in. (10.16 cm) of mercury when measured with
a mercury manometer at the exhaust elbow
outlets. Minimum exhaust hose sizes are given
in the chart below.

MINIMUM EXHAUST HOSE SIZE

Engine Single Dual

MP 5.0L 4 in. (102 mm) 3 in. (76 mm)

MP 5.7L 4 in. (102 mm) 4 in. (102 mm)

MP 6.0L 4 in. (102 mm) 4 in. (102 mm)

MP 8.1L STD 4 in. (102 mm) 4 in. (102 mm)

MP 8.1L HO 4 in. (102 mm) 4 in. (102 mm)

Carb. 5.7L 4 in. (102 mm) 4 in. (102 mm)

6. Exhaust hoses must be connected to the engine
exhaust elbows so that they do not restrict the
fl ow of discharge water from the elbow.

If hoses are connected incorrectly, a hot spot in the hose
can occur, and eventually burn through.

L510023-07

33

Figure 28 Typical Water-Lift Muffl er Exhaust Layout

Exhaust Systems with Water-Lift Muffl ers

WARNING

Boating industry standards (BIA, ABYC, etc.), Federal
standards, and Coast Guard regulations must be
adhered to when designing and installing exhaust
systems.

1. System layout and construction must prevent
cooling system discharge water from fl owing
back into the engine, and also must prevent
seawater from entering the engine via the
exhaust system.

2. The exhaust hoses and pipes must not be higher
than the exhaust elbow outlets at any point.

3. The exhaust system (for routing exhaust to
outside of boat) must be located so that a
minimum of 1 in. per foot (83.31 mm per meter)
downward pitch exists in the exhaust hose
or pipe from the engine exhaust elbow to the
muffl er inlet, and from the muffl er outlet to the
exhaust outlet, with a minimum drop of 4 in. (100
mm) overall (this is an ABYC recommendation).
The drop must be constant so that a low spot
does not exist at any point in the exhaust hose
or pipe.

4. Exhaust outlet(s) should be slightly above the
water line with the boat at rest in the water, and
a full load onboard. Exhaust outlet(s) must be
equipped with an internal shutter and/or exhaust

fl apper to prevent seawater from running back

into the exhaust system.

5. System must not cause excessive back
pressure. Back pressure MUST NOT exceed 4
in. (10.16 cm) of mercury when measured with
a mercury manometer at the exhaust elbow
outlets. Minimum exhaust hose sizes are given
in the chart on page 26.

6. Exhaust hoses must be connected to the engine
exhaust elbows so that they do not restrict the
fl ow of discharge water from the elbow.

NOTICE: There have been instances where the use
of water-lift muffl ers, installed close to the engine, have
caused water to be drawn back into the engine under
certain operating conditions. Crusader has in-line
damper valve assemblies available to help prevent water
ingestion problems.

In-Line Exhaust Damper Valve Kit P/N RK012023

LH Damper Tee Assembly
(4X4X5 in.) P/N 22920

RH Damper Tee Assembly
(4X4X5 in.) P/N 22921

If you have questions regarding the use of water-lift
muffl ers, contact Crusader Engines for clarifi cation.

34

L510023-07

THROTTLE/SHIFT REMOTE CONTROL AND
CABLES

Shift control and shift cable MUST position transmission
shift lever EXACTLY as stated in this manual or
transmission failure may occur. Damage caused
to transmission as a result of improper shift lever
positioning WILL NOT be covered by transmission
manufacturer’s warranty.

IMPORTANT: To ensure proper shift and throttle
operation, control must provide a shift cable travel
of 2-3/4 in. (6.99 cm).

NEUTRAL

1.25 in (3.17 cm)
INLET HOSE

CONNECTION

SEACOCK

REVERSE

GEAR

FORWARD

GEAR

Figure 29 Shift Control

SEAWATER PICKUP CONNECTION

Seawater Pickup and Hose

Water pickup must be large enough to permit suffi cient
water fl ow to the engine seawater pickup pump for
adequate engine cooling [30 gallons per minute (114
liters per minute) minimum]. Pickup must supply a
positive head while underway. Water pickup should
be located as close to the seawater pickup pump inlet
as possible and in an area where an uninterrupted,
solid stream of water will fl ow past, when the boat is
underway.

Connect the water pickup to the seawater pickup pump
inlet with 1-1/4 in. (3.17 cm) I.D. wire reinforced hose
of adequate wall thickness to prevent it from collapsing
from the pump suction. Be sure to secure the hose
connections with hose clamps.

IMPORTANT: DO NOT install the water pickup
directly in line with the propeller, as the pickup
may create turbulence and allow air to fl ow
into the “propeller slipstream.” This will cause
propeller ventilation and will adversely affect boat
performance.

WATER PICKUP

BOAT MOVEMENT

IN FORWARD GEAR

Figure 30 Water Pickup and Seacock

WATER FLOW

SEACOCK SIZE RECOMMENDATION

Seacock used must have an internal cross-sectional
area equal to, or greater than, the hose to prevent
restricting water fl ow. Install the valve in an area where
it will be easily accessible and supported adequately to
prevent hose fatigue. A minimum 1-1/4 in. (3.17 cm)
brass ball or gate valve is recommended.

SEA STRAINER RECOMMENDATION

Strainer used must be of suffi cient size to ensure that an
adequate supply of water will be maintained for cooling
the engine. A minimum of 30 gallons per minute (114
liters per minute) fl ow rate is required.

CRANKCASE OIL DIPSTICK RELOCATION

All Transmissions Except Hurth and Velvet
Drive 5000 Series

Engine crankcase oil dipstick and tube can be located
on either the starboard or port side of the engine to suit
installation requirements. To move the dipstick and tube
to the opposite side of the engine, if necessary, do the
following:

1. Lift the engine with a suitable sling and loosen
the dipstick fi tting on the oil pan. Drain the oil
into a clean, approved container for reuse.

L510023-07

35

2. Remove the bolt retaining the dipstick mounting
clamp. Then, remove the dipstick fi tting at the
oil pan. Loosen the center bolt and rotate the oil
pan fi tting.

3. Put sealer on the dipstick fi tting threads and
reinstall into the oil pan fi tting. Mount and attach
the dipstick in the same manner as it was
removed from the other side.

4. Fill the engine with oil.

DIPSTICK

TUBE

CLAMP

OIL PAN
FITTING

Figure 31 Oil Pan and Dipstick Fittings

PRELIMINARY ENGINE ALIGNMENT

(Mount Adjustment Tool - P/N 22165)

1. Remove the lag screws holding the engine to
the shipping pallet. Attach a suitable sling to the
lifting eyes on the engine. Lift the engine from
the pallet with an overhead hoist.

2. Check the tightness of the engine mounts and
re-torque the mount attaching bolts to 45-50 lb-ft
(61-68 N.m), if necessary.

IMPORTANT: Engine mounts must be adjusted
as explained in Steps 3 and 4 to center mount
adjustment and establish a uniform height on all
mounts.

3. Check all four (4) engine mounts to ensure that
the distance from the bottom of the mount to
the bottom of the trunnion is as shown. If not,
turn the nylon adjusting sleeve in the direction
required to obtain the proper dimension.

4. Loosen the trunnion clamping bolt and nut on
all four (4) engine mount brackets to ensure the
following:

a. Large diameter of the mount trunnion is

extended as shown.

b. Each mount base is downward. Tighten the

trunnion clamping bolts and nuts slightly to
prevent moving in or out. Mounts must be
free to pivot when installing the engine.

Engines Equipped with Hurth and Velvet Drive
5000 Series Transmissions

Engine crankcase oil dipstick can be located either port
or starboard side of the engine, depending on installation
requirements. To move the dipstick, reverse the dipstick
and rubber caps on the dipstick tubes.

ENGINE INSTALLATION

NOTICE TO INSTALLER BEFORE STARTING
INSTALLATION: Read “General Information” and

“Installation Requirements” completely.

TORQUE SPECIFICATIONS

NOTICE: Tighten ALL fasteners (not listed) securely.

Engine Mount Attaching Bolts 45 lb-ft (61 N.m)

Fuel Line Inlet Fitting Securely

Trunnion Clamping Bolt and Nut 45 lb-ft (61 N.m)

Propeller Shaft Coupling Bolt and
Nut 50 lb-ft (68 N.m)

Exhaust Manifold Bolt 20 lb-ft (27 N.m)

0.5 in.

(12.5 mm)

LAG

BOLT

3/8 in.

(9.5 mm)

TRUNNION

BOLT

Figure 32 Preliminary Engine Mount Extension

36

L510023-07

Velvet Drive and Hurth 8 Degree Down Angle
Transmissions

5. Lift the engine into the boat and position it on
the engine bed so that the transmission and
propeller shaft couplings are visibly aligned (no
gap can be seen between the coupling faces
when butted together). Adjust the engine bed
height, if necessary, to obtain proper alignment.
DO NOT use mount adjustments to adjust
engine position at this time.

OFFSET

MISALIGNMENT

PERFECT ALIGNMENT

COUPLING FACES ARE PARALLEL

WITH DISTANCE BETWEEN FACES

EXACTLY THE SAME AT ALL POINTS

ANGULAR

MISALIGNMENT

All Transmissions

IMPORTANT: The engine bed must position the
engine so that a minimum of 1/4 in. (6 mm) up-and­down adjustment still exists on all four (4) mounts
after performing fi nal adjustment. This is necessary
to allow for realigning the engine in the future.

6. Check all four (4) mounts to ensure that they are
still positioned properly, then fasten the mounts
to the engine bed with 1/2 in. (1.27 cm) diameter
lag bolts (of suffi cient length). Tighten the lag
bolts securely.

7. Disconnect the overhead hoist and remove the
sling.

FINAL ENGINE ALIGNMENT

IMPORTANT: Engine alignment MUST BE
RECHECKED with the boat in the water, fuel tanks
fi lled, and with normal load onboard.

You MUST allow 24 hours from the time the boat is
launched until the fi nal engine alignment is checked.
This allows the boat hull to settle into the position
that the engines will run in.

Engine must be aligned so that the transmission and
propeller shaft coupling center lines are aligned and
coupling faces are parallel within 0.003 in. (0.07 mm).
This applies to installations with solid couplings, as
well as fl exible couplings.

1. Check the mating faces on the transmission and
propeller shaft couplings to make sure they are
clean and fl at.

Figure 33 Coupling Flange Alignment

Velvet Drive and Hurth V-Drive Transmissions

5. Lift the engine into the boat and position it
on the engine bed so that the propeller shaft
protrudes thru the transmission output fl ange
coupling. Install the propeller shaft coupling and
then position the engine so that the couplings are
visibly aligned (no gap can be seen between the
coupling faces when butted together). Adjust the
engine bed height, if necessary, to obtain proper
alignment. DO NOT use mount adjustments to
adjust engine position at this time.

Figure 34 Shaft Mating Surface Check - 8 Degree Down

Angle

L510023-07

37

Figure 35 Shaft Mating Surface Check - V-Drives

Figure 37 Centering Propeller Shaft - V-Drives

2. Center the propeller shaft in the shaft log as
follows:

A. Push down and then lift the propeller shaft as

far as it will move, then place the shaft in the
middle of the movement.

B. Move the shaft to the port and then to the

starboard as far as the shaft will move,
then place the shaft in the middle of the
movement.

C. With the propeller shaft in the middle of the

shaft log, align the engine to the shaft.

3. Check that the coupling center lines align by
butting the propeller shaft coupling against the
transmission coupling. The shoulder on the
propeller shaft coupling face should engage
recessed on the transmission coupling face, with
no resistance.

NOTICE: Some propeller shaft couplings may not have a
shoulder on the mating surface. On these installations,
use a straight edge to check the centerline alignment.

4. Check for any angular misalignment. Hold

coupling faces tightly together and check for a
gap between the coupling faces, with a 0.003 in.
(0.07 mm) feeler gauge, at 90-degree intervals.

Figure 36 Centering Propeller Shaft - 8 Degree Down

Angle

38

Figure 38 Angular Alignment - 8 Degree Down Angle

L510023-07

Figure 39 Angular Alignment - V-Drives

5. If the coupling center lines are not aligned, or if
the coupling faces are more than 0.003 in. (0.07
mm) out of parallel, adjust the engine mounts as
follows:

A. UP or DOWN ADJUSTMENT: Loosen the

lag bolt 1/4 turn. Use the mount adjusting
tool or a 3/8 in. (0.95 cm) or 1/2 (1.27
cm) diameter rod through both sides of the
adjusting sleeve to turn. Turn the adjusting
sleeve in the direction required to raise or
lower the engine. After the adjustment is
complete, tighten the lag bolt.

ROD

LOWER

ENGINE

RAISE

ENGINE

Figure 40 Engine Mount Adjustment

IMPORTANT: Both the front mount (or rear mount)
adjusting sleeves must be turned equally to keep the
engine level from side to side.

B. LEFT or RIGHT ADJUSTMENT: Loosen the

trunnion clamping bolt and the nut on all
four mounting brackets. Move the engine to
the left or right, as necessary, to obtain the
proper alignment.

IMPORTANT: The large diameter of the mount
trunnion MUST NOT extend over 1.0 in. (25.4 mm)
from the mounting brackets on any of the mounts.

1.0 in. MAX
(25 mm)

LAG

BOLT

TRUNNION

BOLT

Figure 41 Engine Extension

6. After the engine has been properly aligned,
secure the engine mounts.

7. Connect the propeller shaft coupling to the
transmission coupling. Tighten the coupling
attaching bolts and nuts to the correct
specifi cations.

THROTTLE/SHIFT CABLES

Lubricate the cable ends, then attach to the engine and
transmission.

Attaching/Adjusting Throttle Cable

Your new engine is equipped with an electronic sensor,
the Throttle Control Position sensor, which is used
to command the throttle plate to the desired throttle
position. The TCP sensor is a spring loaded device,
when the throttle cable is disconnected the TCP will
return to its Idle or zero position at rest on the TCP
bracket idle stop. There are two critical positions that
need to be checked when ensuring proper throttle cable
adjustment.

1. Place the remote control throttle lever in the idle
position.

L510023-07

39

2. Install the throttle cable hub into the throttle
cable retaining clip and secure with the cable
clip.

3. Thread the ball joint clevis onto the throttle cable
as far as necessary to line up the ball joint stud
mounted on the TCP throttle arm. The TCP
arm should be on the idle stop by its own return
spring pressure with no additional pressure
supplied by the throttle cable. Tighten the clevis
jam nut when positioned correctly.

Pivot and Clip should be
centered so no tension is
placed on the bracket.

Attaching/Adjusting Shift Cable - Velvet Drive
In-Line and V-Drive Models

IMPORTANT: Velvet Drive Transmission Warranty
is jeopardized if the shift lever poppet ball or
spring is permanently removed, if the shift lever
is repositioned or changed in any manner or if
the linkage between the remote control and the
transmission shift lever does not have suffi cient
travel in both directions.

1. Place the remote control shift lever and
transmission shift lever in neutral position.

2. Install the shift cable hub onto the shift cable
retaining bracket and lock the cable clip.

3. Thread the clevis pin onto the shift cable until
the clevis lines up with the stud attached on the
transmission shift lever.

4. Retract the spring lock on the clevis pin and
attach the shift cable to the ball joint stud.

5. Place the remote control lever in the forward
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.

4. Retract the spring lock on the clevis pin and
attach the throttle cable to the ball joint stud.

5. Place the remote control throttle lever in the full
throttle position. The TCP arm should be near
or just touch the WOT stop of the TCP bracket.

IMPORTANT: It is not necessary for the arm to
touch the bracket stop to achieve 100% throttle.

Check the throttle cable and TCP linkage for any
binding. Return the throttle lever to the neutral
or idle position.

BALL JOINT

CABLE

CLIP

LUBRICATION

POINTS

Figure 42 Typical Throttle Cable Installation

F

N

R

POPPET

BALL

TOWARD

FLYWHEEL

FOR

FORWARD

Figure 43 Shift Lever Positions - Standard Velvet Drive

6. Place the remote control lever in the reverse
gear position and check transmission shift lever
position. The lever must be positioned as shown
for full engagement.

7. If the transmission shift lever is positioned
properly in one gear but no the other, recheck
the shift cable adjustment. If the transmission
shift lever is not properly positioned in either
gear, readjust the shift cable and recheck for
correct shift engagement. If correct positioning
is still not achieved, the remote control does
not provide suffi cient shift travel and must be
replaced.

40

L510023-07

8. Shift remote control lever from forward to
reverse and make sure cable moves freely and
no binding occurs.

PROP SHAFT

ROTATION

DECAL

IDENTIFICATION

TAG

LH

FORWARD

GEAR

FORWARD

GEAR

RH

RH PROP SHAFT ROTATION

LH PROP SHAFT ROTATION

VELVET DRIVE 5000

TRANSMISSIONS

Figure 44 Forward Gear Prop Shaft Rotation - Standard

Velvet Drive

BALL JOINT

CABLE CLIP

Figure 45 Typical Shift Cable Installation

Attaching/Adjusting Shift Cable - Velvet Drive
5000 Series Transmissions

These model transmissions are full reversing
transmissions. Rotation of the output fl ange and
propeller shaft is determined by the hookup of the shift
cable at the remote control before starting the installation
and adjustment procedures.

For left-hand (LH) shaft rotation - the transmission shift
lever must move TOWARD the engine (fl ywheel) when
the remote control shift handle is placed in the forward
position.

For right-hand (RH) shaft rotation - the transmission shift
lever must move AWAY from the engine (fl ywheel) when
the remote control shift handle is placed in the forward
position.

Figure 46 Velvet Drive 5000 Shift Lever Movement vs.

Output Flange Rotation

CABLE CLIP

BALL JOINT

Figure 47 Shift Cable Installation - Velvet Drive 5000

1. Place the remote control shift lever and
transmission shift lever in neutral position.

2. Install the shift cable hub into the shift cable
retaining bracket and lock the cable clip.

3. Thread the clevis pin onto the shift cable until
the clevis lines up with the stud attached to the
transmission shift lever.

4. Retract the spring lock on the clevis pin and
attach the shift cable to the ball joint stud.

L510023-07

41

5. Place the remote control shift lever in the forward
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.

6. Place the remote control shift lever in the reverse
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.

7. If the transmission shift lever is positioned
properly in one gear, but not the other, recheck
the shift cable adjustment. Readjust the shift
cable and recheck for correct shift engagement.

NOTICE: If correct positioning is still not achieved, the
remote control does not provide suffi cient shift travel and
must be replaced.

8. Shift the remote control lever from forward to
reverse and make sure cable moves freely and
no binding occurs.

Attaching/Adjusting Shift Cable - Hurth 630
Series Transmissions

These model transmissions are full reversing
transmissions. Rotation of the output fl ange and
propeller shaft is determined by the hookup of the shift
cable at the remote control before starting the installation
and adjustment procedures.

For left-hand (LH) shaft rotation - the transmission shift
lever must move AWAY the engine (fl ywheel) when
the remote control shift handle is placed in the forward
position.

For right-hand (RH) shaft rotation - the transmission shift
lever must move TOWARD from the engine (fl ywheel)
when the remote control shift handle is placed in the
forward position.

FORWARD

GEAR

FORWARD

GEAR

LHRH

IDENTIFICATION

LABEL

Figure 48 Forward Gear - LH Prop Shaft Rotation -

Velvet Drive 5000

LH PROP SHAFT ROTATION

RH PROP SHAFT ROTATION

HURTH

TRANSMISSIONS

Figure 50 Hurth Shift Lever Movement vs. Output

Flange Rotation

CABLE CLIP

BALL

JOINT

IDENTIFICATION

LABEL

Figure 49 Forward Gear - RH Prop Shaft Rotation -

Velvet Drive 5000

42

Figure 51 Shift Cable Installation - Hurth

L510023-07

1. Place the remote control shift lever and
transmission shift lever in neutral position.

2. Install the shift cable hub into the shift cable
retaining bracket and lock the cable clip.

3. Thread the clevis pin onto the shift cable until
the clevis lines up with the stud attached to the
transmission shift lever.

4. Retract the spring lock on the clevis pin and
attach the shift cable to the ball joint stud.

5. Place the remote control shift lever in the forward
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.

6. Place the remote control shift lever in the reverse
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.

7. If the transmission shift lever is positioned
properly in one gear, but not the other, recheck
the shift cable adjustment. Readjust the shift
cable and recheck for correct shift engagement.

NOTICE: If correct positioning is still not achieved, the
remote control does not provide suffi cient shift travel and
must be replaced.

8. Shift the remote control lever from forward to
reverse and make sure cable moves freely and
no binding occurs.

Figure 53 Forward Gear - RH Prop Shaft Rotation

- Hurth

AUDIO ALARM SYSTEM

WARNING

The buzzer is not external-ignition protected.
Therefore, DO NOT mount buzzer in the engine or
fuel compartments.

Figure 52 Forward Gear - LH Prop Shaft Rotation

- Hurth

1. Select a location for the audio warning buzzer
which meets all of the following requirements:

a. A location where the buzzer can be easily

heard, yet is out of sight

b. A location which is easily accessible for

installation and maintenance.

c. A location where the buzzer will not get wet.

2. Mount the buzzer in desired location.

3. Attach the buzzer to any 12-volt source on
switched side of the ignition switch. TERMINAL
TO WHICH WIRE IS ATTACHED MUST
HAVE NO VOLTAGE WHEN THE IGNITION
SWITCH IS IN THE “OFF” POSITION. Tighten
the connection securely, and coat with liquid
neoprene.

4. Connect tan/blue wire in the instrumentation
wiring harness to the buzzer.

L510023-07

43

EXHAUST SYSTEM CONNECTION

1. Exhaust hoses must be connected to the
exhaust elbows so that they do not restrict the
fl ow of discharge water from the elbow. If the
hoses are connected incorrectly, a hot spot in
the hose can occur, and can eventually burn
through.

2. Exhaust hoses should be secured at each
connection with at least two (2) adequate hose
clamps.

HOT SPOT

INCORRECT CORRECT

Figure 54 Exhaust Hose Connections

ENGINE HARNESS CONNECTION

Install the main engine electrical harness at the 2-Pin
and 8-Pin Deutsch connectors.

CLASSIC 5.7L CARBURETOR ­ENGINE HARNESS CONNECTION

Install the main engine electrical harness plug and clamp
as shown. Tighten the clamp securely.

HARNESS

CLAMP

BATTERY CONNECTION

IMPORTANT: Engine electrical system is negative (-)
ground.

1. Connect the engine positive (+) battery cable
(usually red) to the positive (+) battery terminal.

2. Connect the engine negative (-) battery cable
(usually black) to the negative (-) battery
terminal.

3. Make sure that all the battery terminal
connections are tight. Then, coat the
connections and terminals with a battery terminal
anti-corrosion spray to help retard corrosion.

TWIN ENGINE

MASTER/SLAVE

CONNECTOR

2-PIN BOAT

HARNESS

CONNECTOR

FUEL TANK

SOLENOID

CONNECTOR

8-PIN BOAT

HARNESS

CONNECTOR

Figure 55 Typical Main Engine Electrical Harness

Connection

NOTE: Refer to page 20 for Adapters to
mate to existing boat harnesses.

44

SPEED CONTROL/

CAN BUS

CONNECTOR

L510023-07

NEGATIVE (-)

POSITIVE (+)

CONNECTION

CONNECTION

Figure 56 Battery Terminal Connections

CRUSADER MASTER ENGINE SPECIFICATIONS - 2007

MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L

(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Displacement 5.0L (305 CID) 5.7L (350 CID) 8.1L (496 CID) 8.1L (496 CID) 6.0L (364 CID) 5.7L (350 CID)

Bore 3.75 in. (95.0 mm) 4.0 in. (101.6 mm) 4.25 in. (107.95 mm) 4.25 in. (107.95 mm) 4.0007 in. (101.618 mm) 4.0 in. (101.6 mm)

Stroke 3.48 in. (88.3 mm) 3.48 in. (88.3 mm) 4.370 in. (111.0 mm) 4.370 in. (111.0 mm) 3.622 in. (92.0 mm) 3.48 in. (88.3 mm)

Compression Ratio 9.4:1 9.4:1 9.1:1 9.1:1 9.4:1 9.4:1

Compression Pressure 130 - 215 psi 130 - 215 psi 130 - 175 psi 130 - 175 psi 130 - 215 psi 130 - 215 psi

WOT Operating RPM 4600-5000 (**5100) 4800 - 5200 (**5300) 4400 - 4800 (**4900) 4800 - 5200 (**5300) 4800 - 5300 (**5400) 4800 - 5200

Preferred WOT RPM 4800 5000 4600 5000 5200 5000

Cruising RPM (Max) 3800 4000 3800 4000 4000 4000

Idle RPM (In Gear) 650 (Not Adjustable) 650 (Not Adjustable) 650 (Not Adjustable) 700 (Not Adjustable) 650 (Not Adjustable) 750

Oil Pressure @ 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 80 psi 25 - 60 psi

2000 RPM (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 552 kPa) (172 - 414 kPa)

Minimum Oil Pressure 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa)

at Idle at Idle at Idle at Idle at Idle at Idle Spark Plug P/N R030010 R030010 R030009 R030009 R030011 R030010

L510023-07

Spark Plug Gap 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in.

Firing Order 1-8-4-3-6-5-7-2 (LH) 1-8-4-3-6-5-7-2 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-4-3-6-5-7-2 (LH)

1-2-7-5-6-3-4-8 (RH) 1-2-7-5-6-3-4-8 (RH) NA NA NA 1-2-7-5-6-3-4-8 (RH)

Thermostat FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C)

Over-Temperature 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)

Electrical System 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-)

Ground Ground Ground Ground Ground Ground

Alternator Rating 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps

Ignition Timing Not Adjustable Not Adjustable Not Adjustable Not Adjustable Not Adjustable 26º @ 4000 RPM

CAM Retard 0-4 degrees 0-4 degrees Not Adjustable Not Adjustable Not Adjustable Not Adjustable

Battery Rating 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum)

120 Ah 120 Ah 120 Ah 120 Ah 120 Ah 120 Ah

45

07/07

Engine Specs

CRUSADER MASTER FUEL PRESSURE SPECIFICATIONS - 2007

MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L

(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Fuel Pressure FCC 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 59-62 psi @ WOT

Fuel Pressure - FCC

Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT

w/mounted LPFP

Fuel Pressure mounted 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi

LPFP (WOT) (WOT) (WOT) (WOT) (WOT)

Fuel Pressure - FCC

Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT

w/Remote mount LPFP

Fuel Pressure remote 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi

46

CRUSADER MASTER WARNING/ALARM SPECIFICATIONS - 2007

IMPORTANT: FUEL PRESSURE MEASUREMENT MUST BE MADE WITH THE ENGINE UNDER LOAD.

Exhaust 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F

Over-Temperature M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 N/A

Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp

and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Low Oil < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi

Pressure Sensor or M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 Check Gauges Lamp

(Switch-5.7L carb only) Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

LPFP (WOT) (WOT) (WOT) (WOT) (WOT) (WOT)

MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L

(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

L510023-07

Coolant 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)

Over-Temperature M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 Check Gauges Lamp

Sensor Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Transmission 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F

Over-Temperature M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 Check Gauges Lamp

Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Engine operation above the Maximum RPM listed will appear normal, but will not exceed the (**MAX Governor) RPM listed. This is not

recommended. If the engine is operating above the maximum RPM listed, a higher pitched propeller would be required to lower the engine

**IMPORTANT NOTICE: Crusader engines incorporate an RPM “MAX GOVERNOR” in order to prevent the engine from over-revving.

maximum RPM to the Preferred RPM listed in the chart above.

NOTE: FOR NEW BOAT PROPPING, IT IS RECOMMENDED THAT OEMS PROP TO THE MAXIMUM RPM LISTED.

CRUSADER MASTER ENGINE SPECIFICATIONS - 2007 - SN 671344 and higher

MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L

(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Displacement 5.0L (305 CID) 5.7L (350 CID) 8.1L (496 CID) 8.1L (496 CID) 6.0L (364 CID) 5.7L (350 CID)

Bore 3.75 in. (95.0 mm) 4.0 in. (101.6 mm) 4.25 in. (107.95 mm) 4.25 in. (107.95 mm) 4.0007 in. (101.618 mm) 4.0 in. (101.6 mm)

Stroke 3.48 in. (88.3 mm) 3.48 in. (88.3 mm) 4.370 in. (111.0 mm) 4.370 in. (111.0 mm) 3.622 in. (92.0 mm) 3.48 in. (88.3 mm)

Compression Ratio 9.4:1 9.4:1 9.1:1 9.1:1 9.4:1 9.4:1

Compression Pressure 130 - 215 psi 130 - 215 psi 130 - 175 psi 130 - 175 psi 130 - 215 psi 130 - 215 psi

WOT Operating RPM 4600-5000 (**5100) 4800 - 5200 (**5300) 4400 - 4800 (**4900) 4800 - 5200 (**5300) 4800 - 5300 (**5400) 4800 - 5200

Preferred WOT RPM 4800 5000 4600 5000 5200 5000

Cruising RPM (Max) 3800 4000 3800 4000 4000 4000

Idle RPM (In Gear) 650 (Not Adjustable) 650 (Not Adjustable) 650 (Not Adjustable) 700 (Not Adjustable) 650 (Not Adjustable) 750

Oil Pressure @ 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 80 psi 25 - 60 psi

2000 RPM (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 552 kPa) (172 - 414 kPa)

Minimum Oil Pressure 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa)

L510023-07

at Idle at Idle at Idle at Idle at Idle at Idle Spark Plug P/N R030010 R030010 R030009 R030009 R030011 R030010

Spark Plug Gap 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in. Firing Order 1-8-4-3-6-5-7-2 (LH) 1-8-4-3-6-5-7-2 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-4-3-6-5-7-2 (LH)

1-2-7-5-6-3-4-8 (RH) 1-2-7-5-6-3-4-8 (RH) NA NA NA 1-2-7-5-6-3-4-8 (RH)

Thermostat FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C)

Over-Temperature 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)

Electrical System 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-)

Ground Ground Ground Ground Ground Ground

Alternator Rating 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps

Ignition Timing Not Adjustable Not Adjustable Not Adjustable Not Adjustable Not Adjustable 26º @ 4000 RPM

CAM Retard 0-4 degrees 0-4 degrees Not Adjustable Not Adjustable Not Adjustable Not Adjustable

Battery Rating 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum)

120 Ah 120 Ah 120 Ah 120 Ah 120 Ah 120 Ah

47

07/07

Engine Specs

CRUSADER MASTER FUEL PRESSURE SPECIFICATIONS - 2007 - SN 671344 and higher

MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L

(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Fuel Pressure FCC 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 59-62 psi @ WOT

Fuel Pressure - FCC

Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT

w/mounted LPFP

Fuel Pressure mounted 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi

LPFP (WOT) (WOT) (WOT) (WOT) (WOT)

Fuel Pressure - FCC

Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT

w/Remote mount LPFP

Fuel Pressure remote 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi

48

CRUSADER MASTER WARNING/ALARM SPECIFICATIONS - 2007 - SN 671344 and higher

IMPORTANT: FUEL PRESSURE MEASUREMENT MUST BE MADE WITH THE ENGINE UNDER LOAD.

LPFP (WOT) (WOT) (WOT) (WOT) (WOT) (WOT)

MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L

(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Coolant 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)

L510023-07

Over-Temperature M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 Check Gauges Lamp

Sensor Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Transmission 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F

Over-Temperature M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 Check Gauges Lamp

Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

Exhaust 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F

Over-Temperature M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 N/A

Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp

and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Low Oil < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi

Pressure Sensor or M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 Check Gauges Lamp

(Switch-5.7L carb only) Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

**IMPORTANT NOTICE: Crusader engines incorporate an RPM “MAX GOVERNOR” in order to prevent the engine from over-revving.

and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Engine operation above the Maximum RPM listed will appear normal, but will not exceed the (**MAX Governor) RPM listed. This is not

NOTE: FOR NEW BOAT PROPPING, IT IS RECOMMENDED THAT OEMS PROP TO THE MAXIMUM RPM LISTED.

recommended. If the engine is operating above the maximum RPM listed, a higher pitched propeller would be required to lower the engine

maximum RPM to the Preferred RPM listed in the chart above.

DELIVERY PREPARATION

NOTICE: Before starting the pre-delivery, read “General

Information” and “Installation Requirements” completely.

Test Running the Engine

WARNING

If the engine is to be tested on land, propeller must
be removed.

Pre-Delivery Checklist

IMPORTANT: If the engine is to be tested on land,
water must be supplied to the seawater pickup
pump. DO NOT run engine above 1500 RPM.

Check for Bulletins

Belt and Pulley: Inspect
for Damage

Engine Oil: Check

All Drain Plugs: Confi rm
Proper Installation

Drive Lube: Check All Fuel Lines:

Confi rm No Leaks

Type Information

Battery Rating, Charge, and Level:
Check

Control Adjustments:

All Oil Lines:
Confi rm No Leaks

All Water Lines:

To Prevent

Confi rm Proper Operation
Gauges: Check for

Proper Operation

Confi rm No Leaks
Electrical Wiring: Check

for Proper Installation

Processing Delay

Record Propeller Size, Rotation and WOT - Port
WOT RPM_________Diameter_________ Pitch_________Rotation__________

Record Propeller Size, Rotation and WOT - Stbd
WOT RPM_________Diameter_________ Pitch_________Rotation__________

Port ­Record Fuel Pressure, WOT ______

Dealer Reviewed Warranty

with Owner

NOTICE: The following pages contain detailed steps in order to successfully perform the “Crusader
Pre-Delivery Inspection Procedure.” These steps should be read carefully and completely prior to
performing the inspection.

Starboard ­Record Fuel Pressure, WOT ______

Trouble Codes Checked
Trouble Codes Cleared

L510023-07

49

Pre-Delivery Inspection

REFERENCES: • Crusader Owner’s Operation and Maintenance

Manual

• Crusader Master Engine Specifi cations Sheet

• Boat Owner’s Manual

The Pre-Delivery Inspection ensures the safety and reliability of the Crusader
product. It is necessary that the inspection procedures be performed in the order
given. Crusader recommends that the inspection be accomplished in a timely
manner, allowing time for repairs that may be necessary, prior to the boats delivery
to the customer.

The inspection is laid out in two (2) stages. Stage One is a static, pre-operational
inspection. Stage Two is an operational/sea-trial inspection. After completion of the
Pre-Delivery Inspection you will have the information necessary to accurately and
completely fi ll out the Pre-Delivery Checklist portion of the Warranty Registration
Form.

Stage 1 - Static Pre-Operational Inspection

1. Engine and Transmission Identifi cation.

(Refer to the Crusader Owner’s Operation and Maintenance Manual for Engine

and Transmission Identifi cation location.)

Locate the engine identifi cation tag and record the model and serial number in

the space provide. The Crusader model identifi cation provides you with valuable
information concerning the engine you are working on. Information includes
raw/fresh water cooling, engine rotation, engine type, drive type and function,
propeller shaft rotation, gear ratio, and ignition and fuel type. Also the engine
serial number. This information will be needed for the next step in this procedure
so you can narrow your search for Service Updates to only those associated
with the engine you are preparing to put into service.

ENGINE MODEL NO.

ENGINE SERIAL NO.

Locate the transmission identifi cation tag and record the model and serial

number in the space provide on the inspection procedure.

TRANS. MODEL NO.

TRANS. SERIAL NO.

PORT

STBD

2. Service Update Check

Once you have located the Engine and Transmission Model and Serial numbers

you need to review the Service Updates for any which may apply to the
engine(s) you are preparing for delivery.

Check Crusader Service Updates for USCG Safety Recall and product

enhancement bulletins. Correct any condition that may be discovered, before
proceeding with the Pre-Delivery Inspection Procedure. Note Service Update
number(s) in the space provided and check the compliance box.

50

SERVICE UPDATE #

SERVICE UPDATE(S) INSTALLED:

L510023-07

3. Propeller Identifi cation and Inspection

(Refer to the Crusader Owner’s Operation and Maintenance Manual and the
Crusader Master Engine Specifi cation Sheet for operational parameters based on
propeller selection.)

• Proper boat performance is dependent upon boat design, engine power
and a properly sized propeller. The size markings will be needed if a
performance issue is raised.

• Prior to installation of the propellers, locate the size and rotation markings on
the propeller(s).

• Record the markings, Diameter, Pitch, and Rotation in the space provided
and compare to known standards. If you are unsure of the proper propeller
size, contact the boat manufacturer for the information necessary to
determine the proper size for the boat. Correct any defi ciency.

Diameter:

Pitch:

Rotation:

NOTICE: The boat manufacturer and/or the dealer selects and installs
the propeller(s). Problems that are associated with the propeller(s) or its
installation should be corrected at the direction of the boat manufacturer
and/or installer and are not a Crusader Warranty item.

4. Static Leak Check of Fuel and Oil Lines

Check all fuel and oil lines for leaks. Using your hand check each and every

fuel line and oil line to and on the engine for leaks. Note the location of any
leaks found. Correct any defi ciency. Check the compliance box.

NOTICE: The boat manufacturer and/or the dealer selects and installs the
fuel lines from the fuel tank to the engine. Problems associated with this
fuel line or its installation should be corrected at the direction of the boat
manufacturer and/or installer and are not a Crusader Warranty item.

5. Engine Wiring Inspection

Do a visual inspection to insure that all plug-in connectors of the engine wiring

harness are plugged into their proper devices. Check to insure that the boat
harness is plugged completely and correctly into the engine harness. Correct
any defi ciencies found and check the compliance box.

6. Static, Prelaunch Fluids Check

• Engine and transmission oil levels must be verifi ed prior to engine operation.
These levels will again be checked after operation. Normal levels for both
the engine and transmission should be between the Low and Full marks on
the dipstick. Oil levels must be at least to the low oil level mark at this

time.

• With the boat resting close to its in-the-water position, remove the engine(s)
dipstick(s) and wipe the dipstick(s) clean of oil and insert the dipstick into the
dipstick tube. Be sure that the dipstick bottoms out in the tube.

• Remove the dipstick and note the oil level. Correct any defi ciency for each
engine.

• Remove the dipstick from each transmission, wipe the dipstick clean of oil
and insert the dipstick into the dipstick opening. Be sure that the dipstick
bottoms out on case (Velvet Drive) or to the threads (Hurth - Note: do not
screw the dipstick in when checking fl uid levels.).

• Remove the dipstick from the transmission and note the oil level. Correct
any defi ciency. NOTE: Oil levels slightly above the full mark, at this

time, would be normal. Do Not remove fl uid at this time.

PORT STBD

PORT STBD

PORT STBD

PORT STBD

L510023-07

51

7. Check Water & Exhaust Hoses for Proper Connection

• Attach hoses removed for winterization.

• Inspect each hose for leaks, routing, rubbing and cuts or abrasions. Correct
any defi ciency.

• If equipped, check to insure that the strainer is not damaged and seal is
secure. Correct any defi ciency.

• If equipped, check to insure that the hull inlet valve is turned to its OPEN
position.

• Check Fresh Water Cooling to insure that the coolant level is proper. Coolant
level in the Degas Bottle should be at the ‘MAX’ line on the bottle.

IMPORTANT: The addition of accessories, either by the Dealer or Boat
Manufacturer, i.e. a hot water heater or heater, to the engine’s freshwater
coolant system, increases the volume of the engine’s coolant system and will
require additional coolant to be added. Be sure to use Dex-Cool™ extended
life coolant when topping off the Fresh Water Cooling System.

NOTICE: The boat manufacturer/dealer selects and installs the water/exhaust
hoses and accessories to the engine. Problems associated with these hoses,
accessories, or their installation should be corrected at the direction of the
boat manufacturer and/or installer and are not a Crusader Warranty item.

PORT STBD

8. Install and Tighten all Drain Plugs

• The drain plugs have been removed for shipping or winterization. Before the

engine may be safely started the drain plugs must be installed.

• Insert a plug of the proper size coated with PST (Pipe Sealant with Tefl on by
Loctite or equivalent) into each drain location.

• Tighten each drain plug securely. Caution ! Do Not Over Tighten Or Damage

Could Occur.

• Check the compliance box on the procedure.

9. Visual Check of Belt And Pulley Alignment

NOTE: All Crusader engines currently use a serpentine belt at the front of the
engine. This belt has a self-tensioning system which is non-adjustable.

• Check belt for cuts or other damage. Correct any defi ciency.

• Check the pulleys for damage. Correct any defi ciency.

• Visually inspect for pulley and belt alignment. Correct any defi ciency.

PORT STBD

PORT STBD

52

L510023-07

10. Check Battery Installation And Charge Level

• Check battery(s) cold cranking amps against the minimum recommended
Cold Cranking Amps listed on the Master Engine Specifi cation Sheet.
Correct any defi ciency.

• Check for a properly connected power cable(s) (Red) and ground cable(s)
(Black), at the engine, terminal block/isolator, charger, house battery,
and battery switch(s). Correct any defi ciency.

• Check the electrolyte level (as required) and battery(s) charge. Correct any
defi ciency.

• Always connect the positive (+) cable to the battery(s) fi rst and tighten
securely.

• Connect the negative (-) cable to the battery(s) and tighten securely.

• After following boat manufacturer’s pre-start procedures, turn the Ignition

Switch(s) to the ON position and verify battery voltage on the instrument
panel and remaining gauge cluster reads normal for Key On Engine Off.
Turn the Ignition Switch(s) to the OFF position. DO NOT START THE
ENGINE AT THIS TIME.

• Check the compliance box on the procedure.

NOTICE: Problems that are associated with the battery(s) or installation
should be corrected at the direction of the supplier and/or installer and are

not a Crusader Warranty item.

11. Check Control Adjustment, Direction and Travel

The boat manufacturer and/or the dealer selects and installs the control cables

and control head. Check both the throttle and shift cable in-accordance-with
the boat manufacturers and/or installers instructions.

A minimum inspection of the control cables would include the following: (1)

Throttle and shift in neutral, (2) Shift in forward, throttle in neutral or idle
position, (3) Shift in reverse, throttle in neutral or idle position, and (4) Throttle
at the wide-open-throttle (WOT) position.

When the control is in the neutral position, inspect that the throttle linkage is at

its zero or detent position, with no additional pressure supplied by the throttle
cable to the TCP sensor (SUC-1006-01). Verify that the transmission shift arm
is in its neutral position. With the control moved to its in gear and zero throttle
position, the transmission shift arm should be to its full in gear position (both
forward and reverse positions need to be checked) and the throttle linkage
should still be at its zero throttle position or detent position.

With the throttle at its WOT position the verify the TCP arm is near or just

touches the WOT detent. Adjustments should be made as necessary and in
accordance with the boat manufacturer’s / installer’s instructions and SUC­1006-01.

Check the compliance box on the procedure.

NOTICE: Improper adjustment of the control cables can cause engine
and/or transmission damage. Control cables, their adjustment, or engine/
transmission damage resulting from improper adjustment are not a Crusader
Warranty item.

PORT STBD

PORT STBD

L510023-07

53

Stage 2 - Operational / Sea-Trial Inspection

Boat-in-the-Water Tests

IMPORTANT: Engine alignment MUST BE CHECKED at this time, with the boat
in the water, fuel tanks fi lled, and with a normal load onboard.

WARNING

DO NOT leave the helm unattended while performing any tests.

1. Test Equipment Connection

• With the boat in the water and secured in her slip, locate the Data Link
Connector (DLC) on the engine and connect the Diacom cable from your
computer to the engine.

Note: On twin engine applications, Diacom can only read the engine data from
the engine it is connected to. You must disconnect from the current engine
and reconnect to the other engine when you are instructed.

Verify that the Master/Slave Wiring Harness is installed between engine #1 and
engine #2’s Engine Wiring Harnesses.

• Install the fuel pressure gauge onto the fuel rail or FCC fuel pressure fi tting.
(NOTE: For twin engine applications, you will be instructed on when to
connect the fuel pressure gauge to the second engine.) Readings should
be made with the gauge positioned at the same height as the fi tting to which
it is attached. Consult the Master Engine Specifi cation Sheet for the proper
pressures for the engine being tested.

Check the compliance box.

PORT STBD

PORT STBD

2. Priming the Fuel System and Check for Fuel Leaks

• Turn the Ignition Switch to the ON position (for the engine that the fuel

pressure gauge is currently connected to.) to allow the fuel pumps to run until
they shut off, then turn the Ignition Switch to the OFF position (Ignition switch
must remain in the OFF position for a minimum of 5 seconds in order to reset
the engine’s ECM and allow another pump cycle to occur.). This procedure
may have to be repeated 1-3 times to prime the fuel system. Repeat as
necessary to build fuel pressure to the specifi cation of this engine. Check for
fuel leaks at the fuel pressure gauge connection and all fuel fi ttings. Correct
any leaks before proceeding.

• When the fuel pressure is at the specifi ed level, stop cycling the pumps and
allow the engine to sit for one minute while observing the fuel pressure reading
on fuel gauge. Pressure must remain constant when the fuel pumps are not
operating.

NOTE: While the pumps are operating fuel pressure should be within the

Master Engine Specifi cation range for WOT pressure; after the pumps cut
off pressure will drop slightly but remain constant. If proper pressure is
not displayed or does not remain constant, correct this condition before
proceeding.

• Check for signs of fuel in the engine compartment and all fuel lines for leaks
before starting the engine. Correct any defi ciency prior to proceeding.

• For twin engine applications: Relieve the fuel pressure and disconnect

the fuel gauge from engine #1, connect the fuel gauge to engine #2 and
repeat the priming and fuel leak check for engine #2.

Check the compliance box.

54

L510023-07

3. Engine at Idle Check

Follow boat manufacturer’s starting procedures regarding the blower, etc.

Start the engine.

WARNING! If fuel and/or oil leaks are present shut off the engine(s)
immediately.

• Check to insure that the raw water pump is pumping water( both engines)
then allow the engine(s) to idle for approximately one minute. Shut the
engine(s) off. Check each fuel line and fi tting for leaks by running your
clean, dry hand along and under every fuel line and fi tting. Correct any
defi ciency prior to proceeding.

• With clean dry hands, check each oil line and fi tting for leaks by running
your clean, dry hand along and under every oil line and fi tting. Correct any
defi ciency prior to proceeding.

• With clean dry hands, check each water hose and fi tting for leaks by running
your hand along and under every water hose and fi tting. Correct any
defi ciency prior to proceeding.

• Start the engine(s), then check each exhaust hose and fi tting for leaks by
running your hand along and under every engine exhaust outlet hose and
fi tting. Correct any defi ciency prior to proceeding.

• Check each engine’s pulleys for wobble. Correct any defi ciency.

• Cycle each transmission, at idle RPM, from Neutral-Forward-Neutral­Reverse-Neutral.

• Shut the engine(s) off and leave the test equipment attached to the engine.

NOTE: Immediately proceed to the Transmission Fluid check after

shutting the engines off. False fl uid readings can be obtained as the
fl uid returns to the transmission from the oil cooler and its lines.

Check the compliance box.

4. Engine and Transmission Fluid Check

PORT STBD

PORT STBD

Transmission:

• On each transmission, wipe the dipstick clean of oil and insert the dipstick
into the dipstick opening. Be sure that the dipstick is fully inserted into the
case (Velvet Drive) or inserted to the threads, but not screwed in (Hurth).

• Remove the dipstick from the transmission and note the oil level. Correct
any defi ciency.

• Correct any low oil defi ciency by adding the proper amount of oil, that meets
the specifi cation stated on the engine specifi cation decal, to bring the oil to
the full mark. Correct an over-fi lled condition by removing oil until the level
reading on the dipstick is at the full mark.

Engine:

• On each engine remove the dipstick and wipe the dipstick clean of oil, then
insert the dipstick into the dipstick tube. Be sure that the dipstick bottoms
out in the tube.

• Remove the dipstick and note the oil level. Correct any defi ciency.

• Correct a low oil level condition by adding the proper amount of oil, that
meets the specifi cation stated on the engine specifi cation decal, to bring the
oil to the full mark. Correct an over-fi lled condition by removing oil until the
level reading on the dipstick is at the full mark.

Check the compliance box.

PORT STBD

L510023-07

55

5. ECM-07 System Check

A check of the engine management system is done to insure that the EFI

system has not been damaged or modifi ed since shipment from Crusader.

• With the Diacom loaded and set to Crusader’s standardized screen, turn the
ignition switch(s) to the ‘ON’ position (Do Not start the engine(s)) and check
the engine(s) for codes. If codes are present, make a note of them, in the
space provided on the Pre-Delivery Inspection Procedure, and then erase the
codes using the ‘Pencil with Eraser’ icon button on the Diacom screen.

• If any code returns after the erase procedure is performed, the problem is still
in the circuit indicated by the code and must be corrected by the technician
before proceeding.

NOTES: CODES:

• When the system tests code-free, you may proceed to start the engine(s).

NO CODES:

• **ECM-07 Engines: After starting the engine(s), for 5.0L and 5.7L engines
only, CAM Retard must be checked, using Diacom, and verifi ed to be
between 0 to 4 degrees. If CAM Retard is not between 0 to 4 degrees
it must be set to the proper specifi cation. Consult Crusader Service
Update # SUC-0706-01 for the procedure to be used to correct CAM
Retard.

For Twin Engine Applications, disconnect Diacom from the current engine and
connect Diacom to the other engine. Repeat the CAM Retard check/adjustment for
the other engine.

PORT STBD

CAM RETARD:

Check the compliance box.

6. Instrumentation Check

• The gauges on the boat’s instrument panel are the operator’s insight into

the engine’s vital signs. Constant monitoring of the gauges is necessary to
insure that abnormal conditions are recognized as soon as possible to prevent
engine damage and/or dangerous conditions from occurring.

• Allow the engine(s) to come up to normal operating temperature.

• Verify coolant fl ow and level at the Degas Bottle on the engine(s). Correct any
defi ciency. Caution! The Degas Bottle operates under pressure. Allow

the engine to cool suffi ciently before removing the Degas Bottle Cap to
add fl uid.

• Check and verify proper operation of all gauges. Correct any defi ciency.

NOTICE: The boat manufacturer and/or the dealer selects and installs the
instrument panel and gauges. Problems associated with the instrument panel
and gauges or their installation should be corrected at the direction of the boat
manufacturer and/or installer and are not a Crusader Warranty item.

Check the compliance box.

PORT STBD

56

L510023-07

7. Engine Performance Test

• All gauges and test equipment should be observed as frequently as possible
to allow the operator to react quickly to any discrepancy displayed. The
operator must also listen for unusual sounds, feel for unusual vibrations,
smell for signs of fuel, smoke, etc. and look for any sign of abnormal
operational characteristics.

• Verify normal operation and readings on all gauges.

• When conditions permit, accelerate to bring the boat on plane and to a

cruising speed of 3600 RPM. While frequently observing the gauges,
operate the boat at this speed for fi ve minutes.

• After fi ve minutes at 3600 RPM, move the throttle to wide-open-throttle
(WOT) and run at this speed (not to exceed 30 seconds) until the RPMs
have stopped increasing. Note and record the WOT RPM and fuel pressure
at WOT. Reduce the throttle to 3600 RPM.

• Operate the engine(s) at 3600 RPM for an additional 10 minutes while

frequently observing the gauges.

• Return to idle.

• For twin engine applications: Shut off both engines, then relieve the

fuel pressure and disconnect the fuel gauge from engine #1, connect
the fuel gauge to engine #2, re-start the engines, then as conditions
permit, accelerate to bring the boat on plane and to a cruising speed
of 3600 RPM. Operate the boat at this speed for approximately one
minute, then move the throttle to wide-open-throttle (WOT) and run at
this speed (not to exceed 30 seconds) until the RPMs have stopped
increasing. Note and record the fuel pressure at WOT for engine #2.

• Return to idle.

WOT RPM:

FUEL PRESSURE - WOT:

8. Diacom Record of Engine Performance (Optional)

• Record the following water test for your records, using the Diacom ‘Record’

feature. This recording is to be made after all defects, if any are found, have
been corrected. The record time for this procedure will easily fi t on a 3 1/2”
fl oppy disk making it easily accessible for future retrieval, reference and
storage.

NOTE: 2007 Engines: For Twin engine applications, Diacom will have to be

connected to the other engine and the procedure repeated so you
will have a recording of both engine’s parameters.

1. Start the Diacom record function.

2. Idle for 10 seconds.

3. Run at 1,000, 2,000, 3,000, and 4,000 RPMs for 10 seconds each.

4. Return to idle for 10 seconds.

5. Accelerate to 3600 RPM and run @ 3600 RPM for 30 seconds.

6. Accelerate to WOT and run at WOT until the RPM’s stop increasing (not to

exceed 30 seconds).

7. Return the throttle(s) quickly to idle and allow the engine(s) to idle for 10

seconds, then stop the recording.

8. Save the recording, using the engine(s) serial number as the fi le name.

• Return to the dock, check the engine(s) for leaks (water, oil and fuel) and

correct any leaks noted. Turn off the engine(s), recheck the fl uid levels in
the transmission(s) and engine(s) and correct as necessary.

• Review the test data and compare the results to the Master Engine

Specifi cation Sheet. If defects were noted, correct all, then retest the boat.

• Disconnect the test equipment and prepare the boat for customer delivery.

Check the compliance box.

PORT STBD

PORT STBD

L510023-07

57

9. Lay-Up Engine (OPTIONAL)

CAUTION

If the engine will not be used for an extended period of time, or will be exposed
to freezing temperatures, drain the water from the cooling system, as explained
in the “Owner’s Operation and Maintenance Manual.” Water MUST BE drained
to prevent corrosion and freeze damage to the engine.

CAUTION

If the new engine is test run and actual customer usage is not anticipated with
a seven-day period, the engine must be put back into a preserved state by
fogging the cylinders with rust-preventive oil. See the “Owner’s Operation and
Maintenance Manual.”

Check the compliance box.

10. Complete the Pre-Delivery Checklist

Obtain the Crusader Warranty Registration Form that came with the engine.

Using the data obtained and recorded on the Pre-Delivery Inspection Procedure
complete the following blocks on the Warranty Registration Form:

Complete the Pre-Delivery Checklist by checking each box and fi ling in the

required data to signal compliance.

PORT STBD

Engine Model No. (Port and Starboard)
Engine Serial No. (Port and Starboard)
Transmission Serial No. (Port and Starboard)
Check for Bulletins
Engine Oil: Check
Drive Lube: Check
Battery Rating, Charge, and Level: Check
Control Adjustments: Confi rm Proper Operation
Gauges: Check for Proper Operation
Record Propeller Size, Rotation, and WOT:
Port: WOT RPM Diameter Pitch Rotation
Stbd: WOT RPM Diameter Pitch Rotation
Record Fuel Pressure:
Port: WOT
Stbd: WOT
Belt and Pulley: Inspect for Damage
All Drain Plugs: Confi rm Proper Installation
All Fuel Lines: Confi rm No Leaks
All Oil Lines: Confi rm No Leaks
All Water Lines: Confi rm No Leaks
Electrical Wiring: Check for Proper Installation
Trouble Codes Checked / Trouble Codes Cleared

Your Diacom recording and these Pre-Delivery procedure sheets can be

archived either by engine serial number, owner’s name, or both for future
reference by the technician.

58

L510023-07

11. Register the Engine with Crusader

When the boat is sold, you will complete the remaining blocks of the Warranty

Registration Form. Completely fi ll in the required information.

Owner’s Name Date of Sale

Address Selling Dealer
City, State, Zip Address
Boat Make, Length, Type

You should review the Crusader 2 Year Transferable Limited Warranty with the

new owner. Upon completion of the warranty review, you will complete the
remaining dealer portion of the Crusader Warranty Registration form by fi lling
in the following blocks.

Dealer Reviewed Warranty with Owner (the last block of the Pre-Delivery

Checklist)

Dealer Signature: (By signing this form, the dealer certifi es that he has

checked the installation and operation of the engine(s) and
fi nds them to be performing properly.)

Owner’s Signature and Date

Give the customer their copy of the completed Crusader Warranty Registration

form along with the copy of the Warranty Statement. Affi x proper postage and
send the pre-addressed card to Crusader. This completes the registration of a
new Crusader engine.

PORT STBD

L510023-07

59

EXHAUST INSTALLATION GUIDELINES

The top of the exhaust riser must be a minimum of 12 inches above the water line
with the boat at rest and a full load aboard. It is recommended by the ABYC, and
a Pleasurecraft Engine Group requirement, that there be a drop in the exhaust run
between the engine and exhaust outlet of a minimum of 1 inch per foot of run, with a
minimum of four (4) inches drop overall. The drop must be constant so that no low
spots exist at any point in the exhaust hose. The above are minimum guidelines for
installation, however, meeting the minimum guidelines will not necessarily insure
no water intrusion under all operating conditions. It is the responsibility of the boat
builder to confi rm, for each model, that under any and all running angles and other
conditions of operation, no water ingestion will occur.

EXHAUST OUTLET MUST HAVE
INTERNAL SHUTTER AND/OR
EXHAUST FLAPPER INSTALLED

EXHAUST SYSTEM DROP MUST BE
1" PER FOOT OR MINIMUM 4" TOTAL

B

A

A - B = 12" MINIMUM

60

L510023-07

ENGINES

Crusader

L510023-07

61

SEN

I

GNE

red

a
s

u
rC

62

L510023-07

L510023-07

63

ENGINES

Crusader

64

L510023-07

L510023-07

65

66

L510023-07

L510023-07

67

68

L510023-07

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69

70

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71

72

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73

74

L510023-07

A

A

CRUSADER MARINE ENGINES

DISTRIBUTORS

Marysville

Marine

Engine

Distributors

Engine

Distributors

Engine

Distributors II

Engine Distributors Inc.

400 University Court
Blackwood, NJ 08012
Jaime Cummins
Phone: [phone]
Fax: [phone] - Parts
Fax: [phone] - Sales

[e-mail]

Trans Pacific

Marysville Marine Distributors

Trans Pacific Distributors

AER Supply

Engine Distributors Inc.

Trans Pacific Distributors

1941 Walters Court
Fairfield, CA 94533
Henry Bramhall - Owner

rley Harty
Phone: [phone]
Fax: [phone]

[e-mail]

ER Supply

2301 NASA Road One
PO Box 349
Seabrook, TX 77586
Richard Miller
Phone: [phone]
Fax: [phone]

aersupply.com

AER Supply

Marysville Marine
Distributors

282 Progress Way
Sun Prairie, WI 53590
Brian Hunter
Phone: [phone]
Fax: [phone]

marysvillemarine.com

Marysville Marine
Distributors

1551 Michigan Avenue
Marysville, MI 48060
Steve Riehl
Phone: [phone]
Fax: [phone]

marysvillemarine.com

Marysville Marine
Distributors

127 Industrial Dr.
White House, TN 37188
Randy Hall
Phone: [phone]
Fax: [phone]

marysvillemarine.com

Engine Distributors -

Jacksonville

Engine Distributors -

Ft. Lauderdale

Engine Distributors Inc.

41 Pope Road
Holliston, MA 01746
Jaime Cummins
Phone: [phone]
Fax: [phone] - Parts
Fax: [phone] - Sales

[e-mail]

Engine Distributors Inc. II

303 Interstate Dr.
Archdale, NC 27263-3148
Jaime Cummins
Phone: [phone]
Fax: [phone] - Parts
Fax: [phone] - Sales

[e-mail]

Engine Distributors ­Jacksonville

259 Ellis Road South
Jacksonville, FL 32254
Jaime Cummins
Phone: [phone]
Fax: [phone] - Parts
Fax: [phone] - Sales

[e-mail]

Engine Distributors - Ft.
Lauderdale

2917 SW 2nd Avenue
Ft. Lauderdale, FL 33315
Jaime Cummins

Phone: [phone]Phone: [phone]

Fax: [phone] - Parts
Fax: [phone] - Sales

[e-mail]

L510023-07

75

E N G I N E S

INSTALLATION DRAWINGS

APPENDIX - A

Captain’s Choice

XLi SERIES

L510023

and

Engines

11/06

This Page Was

Intentionally Left

Blank

INSTALLATION DRAWINGS:

EXHAUST SYSTEM INSTALLATION GUIDELINES ....................................................................... A-2

CAPTAIN’S CHOICE INSTALLATION DRAWINGS:

5.7L BOSCH / VELVET DRIVE 72 REDUCTION ........................................................................... A-3

5.7L BOSCH / HURTH 630 8° DOWN ANGLE

5.7L BOSCH / HURTH 630V

5.7L BOSCH / VELVET DRIVE 72 DIRECT DRIVE

6.0L W/4 IN. RISERS / HURTH 630 8° DOWN ANGLE

8.1L / HURTH 630A 8° DOWN ANGLE

8.1L / VELVET DRIVE 72 DIRECT DRIVE

8.1L / VELVET DRIVE 72 REDUCTION

..................................................................................................... A-5

........................................................................................ A-8

..................................................................................... A-10

.............................................................................. A-4

........................................................................ A-6

................................................................... A-7

.................................................................................... A-9

XLI INSTALLATION DRAWINGS:

350 XLI-HT / VELVET DRIVE 5000 - 8° DOWN ANGLE ................................................................ A-11

350 XLI-HT / VELVET DRIVE 5000 V-DRIVE
350 XLI-HT / HURTH 8° DOWN ANGLE
350 XLI-HT / HURTH V-DRIVE

350 XLI-HT / VELVET DRIVE 71 DIRECT DRIVE
350 XLI-HT / VELVET DRIVE 72 REDUCTION
350 XLI-HT / VELVET DRIVE 72 V-DRIVE

454 XLI / VELVET DRIVE 5000 - 8° DOWN ANGLE

454 XLI / VELVET DRIVE 5000 V-DRIVE
454 XLI / HURTH 8° DOWN ANGLE
454 XLI / HURTH V-DRIVE

454 XLI / DIRECT DRIVE .......................................................................................................................

454 XLI / VELVET DRIVE 72 REDUCTION
454 XLI / VELVET DRIVE 72 V-DRIVE
454 XLI / VELVET DRIVE DIRECT WITH INTEGRAL WALTERS

502 XLI / VELVET DRIVE 5000

502 XLI / VELVET DRIVE 5000 V-DRIVE
502 XLI / HURTH 8° DOWN ANGLE
502 XLI / HURTH V-DRIVE
502 XLI / DIRECT DRIVE
502 XLI / VELVET DRIVE 72 REDUCTION

502 XLI / VELVET DRIVE DIRECT WITH INTEGRAL WALTERS
350 XLI / VELVET DRIVE 5000 8° DOWN ANGLE
350 XLI PLUS / VELVET DRIVE 5000 V-DRIVE
350 XLI PLUS / HURTH 8° DOWN ANGLE
350 XLI PLUS / HURTH V-DRIVE
MP 454 XLI / VELVET DRIVE 5000 - 8° DOWN ANGLE
MP 454 XLI / VELVET DRIVE 5000 V-DRIVE

MP 454 XLI / HURTH 630 - 8° DOWN ANGLE

MP 454 XLI / HURTH 630 V-DRIVE

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EXHAUST INSTALLATION GUIDELINES

The top of the exhaust riser must be a minimum of 12 inches above the water line
with the boat at rest and a full load aboard. It is recommended by the ABYC, and
a Pleasurecraft Engine Group requirement, that there be a drop in the exhaust run
between the engine and exhaust outlet of a minimum of 1 inch per foot of run, with
a minimum of four (4) inches drop overall. The drop must be constant so that no low
spots exist at any point in the exhaust hose. The above are minimum guidelines for
installation, however, meeting the minimum guidelines will not necessarily insure
no water intrusion under all operating conditions. It is the responsibility of the boat
builder to confi rm, for each model, that under any and all running angles and other
conditions of operation, no water ingestion will occur.

EXHAUST OUTLET MUST HAVE
INTERNAL SHUTTER AND/OR
EXHAUST FLAPPER INSTALLED

EXHAUST SYSTEM DROP MUST BE
1" PER FOOT OR MINIMUM 4" TOTAL

B

A

A - B = 12" MINIMUM

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Crusader

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SEN

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GNE

red

a
s

u
rC

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ENGINES

Crusader

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