PCM 2003 5.0L MPI, 2003 5.7L MPI, 2003 6.0L MPI, 2003 8.1L MPI (HO), 5.0L MPI Owner's Operation And Maintenance Manual

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OWNER’S OPERATION

and

MAINTENANCE MANUAL

A Division of

Thank you for your selection of Pleasurecraft (PCM) Marine Power for your boating needs. We welcome you to Team PCM, which puts you in the company of tens of thousands of boaters who have relied on Pleasurecraft inboards as their power of choice for over 20 years.

When you chose PCM, 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. The pyramidal exhaust system, light-weight transmission, computerized engine control and the Fuel Control Cell (FCC) are all PCM innovations. No matter which PCM 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 starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand any portion of the manual, contact your Dealer for clariﬁ cation or assistance. Ask your Dealer for a demostration of actual starting and operating procedures.

The descriptions and speciﬁ cations contained in this manual were in effect at the time of printing. PCM 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 PCM engines: Year Model 2003 5.0L MPI

2003 5.7L MPI

2003 6.0L MPI

2003 8.1L MPI (HO)

Part Number - L510010-03 Printed 3/03

TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................... 3-5

Registration Information (Warranty Registration Card is located at the back of this manual) 3-Y ear Transferable Limited Warranty California Emission Control Warranty Statement PCM Model Years 2003-2008 General Emissions Warranty Coverage

Safety Information

Replacement Parts ......................................

Safety Warnings BOATING RESPONSIBILITY Carbon Monoxide Hazard

Safe Boating Suggestions Water Wisdom Operation and Maintenance

Rules of the Road

ENGINE IDENTIFICATION Engine Identiﬁ cation Owner Identiﬁ cation and Registration Information

2003 Model Identiﬁ cation / Advisory

ELECTRONIC FUEL INJECTION INFORMATION

Electronic Fuel Injection System Power Reduction Mode OPERA TING INSTRUCTIONS

Engine Alarm System

Instrumentation Starting Engine (Fuel Injected Engines)

Shifting Transmission

Stopping Engine Freezing Temperature Operation

Operation in High Debris Areas

CONDITIONS AFFECTING OPERATION Trim and Weight Distribution Boat Bottom Propeller Selection

ENGINE BREAK-IN PERIOD 25-HOUR ENGINE INSPECTION FUEL REQUIREMENTS

Gasoline Requirements

Gasoline Containing Alcohol OIL REQUIREMENTS Engine Oil Recommendations

Transmission and “V”-Drive Oil Requirements ENGINE MAINTENANCE Engine Maintenance

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TABLE OF CONTENTS

Checking Fluid Levels ........................................................................................................... 27-28

Lubrication Electrical System Circuit Breaker(s) Electrical System Fuses Ignition Fuse

Electrical System Wiring and Connectors Battery Fresh Water Cooling System Sacriﬁ cial Zinc Anode

Checking Coolant Level Flushing Cooling System - Sea-Water Section

Testing Coolant For Alkalinity

Draining Fresh-Water Cooling System Filling Fresh-Water Cooling System Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only)

Fuel System Description Fuel Control Cell (FCC) Fuel System Servicing the FCC

Draining the FCC Bowl, ENGINE OFF Filter Element Replacement, ENGINE OFF

Primary Fuel Filter

Priming Fuel System

Flame Arrestor Accessory Drive Belt

Changing Oils

Engine Alignment Engine Maintenance Log

Maintenance Schedule

Visual Inspection

Engine Fluid Capacities Transmission Fluid Capacities Filter Requirements

ENGINE SPECIFICATIONS OUT-OF-SEASON STORAGE

Engine Storage Draining Instructions

Battery Storage Fitting Out After Storage

TROUBLESHOOTING

WATER FLOW DIAGRAMS INSTRUMENTATION WIRING DIAGRAM

LITERATURE FORMS NOTES

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REGISTRATION INFORMATION (Warranty Registration Card is located at the

back of this manual)

Shortly after your purchase is registered with PCM, you will be mailed your Warranty Card and a Customer Survey. We appreciate your feedback and encourage you to ﬁ ll out the survey after you have had a chance to run your boat for several weeks. We take this input very seriously, and have implemented many of the ideas our customers have given us through this survey. You may also visit our website at www. pleasurecraft.com.

Again, thanks for choosing PCM. We sincerely wish you happy days on the water.

INTRODUCTION - 1

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INTRODUCTION - 1

3 Year Transferable Limited Warranty

Pleasurecraft Marine Engine Co. (PCM) warrants its new products to be free from defects in material and workmanship under normal use and service conditions, to the ﬁ rst

registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases. All components of PCM products are covered under the PCM Warranty, except for those components that are warranted by PCM’s suppliers. The obligation of PCM hereunder shall be limited to the repair or replacement with new or remanufactured components, at its option, of any product or parts thereof which has failed during the period of warranty and which is demonstrated upon examination to have failed due to defective material and/or workmanship. PCM’s policy is one of continued improvement of its products and PCM hereby reserves the right to improve and change the design and production of any of its products without assuming any obligation to modify products previously manufactured and/or sold.

NO OTHER WARRANTY GIVEN

The obligations set forth in the preceding paragraph are PCM’s sole obligation and owner’s exclusive remedy. PCM makes no other express warranty to the extent that any additional warranty may be implied by law, the term of such implied warranty shall be limited to the warranty term stated herein, from the date of delivery of the PCM product to the parties outlined herein.

No distributor, dealer, agent or employee of PCM is authorized to grant any other or further warranty or incur any additional warranty obligation on PCM’s behalf, in connection with the sale of its products. Any qualiﬁ cation or restriction contained herein which is prohibited by any law of mandatory application shall be deemed to be deleted herefrom, however, such deletion

shall have no effect on the remaining provisions hereof, all of which shall remaining full force and effect.

REMEDIES

The obligations of PCM set forth in the ﬁ rst paragraph of this Warranty shall be the exclusive remedy for any breach of Warranty hereunder, and any owner or user’s sole remedy in the event of breach of the warranties which are made by PCM is repair or replacement of the product or any warranted part thereof as set forth herein: with this sole exception, PCM shall not be liable for any direct, or indirect, incidental or consequential damages, including without limitation, any damages for property damage, loss of use or loss of proﬁ ts, loss of income, inconvenience, trailering, towing, haul out, launch and/or any other in and out of water expenses, storage charges, dockage charges, expenses to deliver or pick up the product being warranted to and from the dealer, telephone expenses, lodging expenses, travel expenses, mechanic travel time and mileage, damage caused by any occurrence of an insurable nature, rental of substitute equipment of any type, removal and replacement and/or modiﬁ cation of any boat parts to facilitate repairs, moving of furniture, carpets, cleaning, painting, carpenter work, or re-delivery charges. Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. Any owner or user hereby waives for himself/herself/itself and his/her/its successor and assigns (a) any and all claims for punitive damages, and (b) all claims of

negligence or strict liability or both, In no event will PCM’s liability exceed the purchase price of the goods which is actually paid to PCM.

WARRANTY COVERAGE, TERM

This Warranty is extended only to the ﬁ rst registered owner or registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases, for the period speciﬁ ed below: All components, other than and those itemized below, are warranted for a period of three (3) years from the date of delivery to the ﬁ rst registered owner or registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases in non-commercial use. In case of commercial use, the term of this Warranty shall be the shorter of (a) a period of six (6) months from the date of delivery to the ﬁ rst registered owner or registered user or (b) the expiration of 200 hours of use. Items not covered under this warranty; (A) Water pump impellers are not covered by this Warranty. (B) Seals, gaskets, O-rings, and other material affected by time are not covered by this Warranty if their effectiveness is reduced by an extended storage period prior to sale or use. (C) Components supplied by the Ford Motor Co. are warranted by the Industrial Engine Division of the Ford Motor Co. and are not covered by this Warranty.

OBTAINING PERFORMANCE UNDER WARRANTY

PCM’s warranty registration form should be prepared by your selling dealer, executed by you and the dealer and mailed, by you, to PCM within 30 days after the date of purchase. Upon receipt of the warranty registration form, PCM will issue to you a personalized owner’s registration card which will be mailed directly to you. If the owner’s registration card is not received within eight (8) weeks after the date of purchase, please write PCM at the address below. At the time that a claim for warranty service is made, the owner’s registration card should be presented to the person or entity providing warranty service. Authorized PCM dealers or distributors are entitled to be reimbursed by PCM for some or all of the expense of warranty repairs, thus, service under the terms of this Warranty will be performed by an authorized PCM dealer or distributor without charge for established ﬂ at rate labor or replacement parts, other than items not covered by the Warranty, such as , but not limited to, lubricants, spark plugs, points, and other items which are normally frequently replaced as part of routine maintenance. Charges for additional non-warranty work and/or additional dealer charges for labor relative to warranty work in excess of ﬂ at rate must be paid for by the owner. Prior authorization in writing must be obtained from PCM for any warranty repairs over $50.00 and in all cases where the owner fails to establish the purchase and warranty expiration dates with the owner’s registration card sent upon receipt of the warranty registration form by PCM. While failure to present the owner’s registration card will not prevent you from obtaining coverage hereunder, this Warranty shall not be effective and, therefore, cannot be honored until the product purchase date can be conﬁ rmed by PCM. If the card is lost, communicate with PCM at the address listed below, and, for a processing fee of $10.00, a new owner’s registration card will be issued to you. Any questions concerning service, parts or this Warranty should be directed to your selling dealer. If your dealer is unable to assist or if you relocate or are travelling or need a

referral to your nearest dealer contact: Pleasurecraft Marine Engine Co., P.O. Drawer 369, Little Mountain, SC 29075

FAILURES EXCLUDED FROM WARRANTY

This Warranty will not apply to any failure which results from accidents, sinking, ﬁ re, neglect, abuse, or abnormal service or use, such as racing, towing or operation in water of insufﬁ cient depth, or to any failure resulting from improper installation, improper adjustments, repairs or improper delivery service, or to any failure resulting from the use of parts, fuels, oils or lubricants not suitable for use with the product and/or materials or parts not approved by PCM. This Warranty does not apply to any engine or drive which has been modiﬁ ed, or altered, or repaired in such a manner as, in the opinion of PCM, to affect its stability, reliability or performance. Further, this Warranty will not apply to failure resulting from use of non-recommended lubricants or fuels, failure to follow maintenance or lubrication schedules, failure caused or contributed to by contaminated fuel, failure caused by improper installation or misapplication of the engine or drive, failure resulting from the owner’s or operator’s failure to exercise due or normal care and precaution, or failure of components and/or assemblies

that are warranted by PCM suppliers.

OWNER’S RESPONSIBILITY

Performance under this Warranty shall be conditioned upon the ﬁ rst registered owner’s or registered users’s compliance with the following requirements: 1 Owner or user shall verify that the pre-delivery service has been performed, all requested information recorded and that the selling dealer has signed the warranty registration. 2 Owner or user shall promptly mail the warranty registration to PCM after accepting delivery. 3 Owner or user shall follow the instruction in the owner’s manual regarding operation, break-in, lubrication, and fuel.

4 Owner or user shall follow or comply with the maintenance schedule, operation limits, and lay up instruction, as outlined in the owner’s manual.

CHOICE OF LAW

This Limited Warranty shall be governed by, and construed and interpreted in accordance with, the laws of the State of Ohio, except only to the extent replaced or precluded by other law of mandatory application.

SPECIAL STATE LEGAL REQUIREMENTS

This Warranty gives you speciﬁ c legal rights, and you may also have other rights which vary from State to State. The PCM California Model Years 2003-2008 Emissions Warranty and California Emissions Control Warranty Statement is a separate document included in this Manual. Any questions concerning the Emissions Warranty can be obtained by calling 1-803-345-0050.

INTRODUCTION - 1

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Pleasurecraft Marine Engine Co. (hereinafter “Pleasurecraft”) are pleased to explain the emission control system warranty on your Model Years 2003-2008 inboard engine. In California, new inboard engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Pleasurecraft must warrant the emission control system on your inboard engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your inboard engine.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Pleasurecraft will repair your inboard engine at no cost to you, including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE:

Select emission control parts from Model Years 2003-2008 inboard engines are warranted for 2 years.

OWNER’S WARRANTY RESPONSIBILITIES:

- As the inboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Pleasurecraft recommends that you retain all receipts covering maintenance on your inboard engine, but Pleasurecraft cannot deny warranty coverage solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

- As the inboard engine owner, you should however be aware that Pleasurecraft may deny you warranty coverage if your inboard engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modiﬁ cations.

- You are responsible for presenting your inboard engine to a Pleasurecraft distribution center as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed thirty (30) days.

If you have any questions regarding your warranty rights and responsibilities, you should contact Pleasurecraft at 1-803-345-0050.

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INTRODUCTION - 1

PLEASURECRAFT MARINE ENGINE CO. MODEL YEARS 2003-2008 GENERAL

EMISSIONS WARRANTY COVERAGE

1. Pleasurecraft Marine Engine Co. (hereinafter referred to as “Pleasurecraft”) warrants to the ﬁ rst owner purchasing at retail, and all subsequent owners, of every Pleasurecraft Model Years 2003-2008 inboard engine that the emissions control devices on Pleasurecraft inboard marine engines are free from defects in materials and workmanship when manufactured and will remain so for a period of two (2) years from the date of delivery to the ﬁ rst owner purchasing the engine at retail or from the date the engine is ﬁ rst placed into service for demonstration or any other purpose prior to sale to the ﬁ rst owner purchasing the engine at retail.

2. Pursuant to the California Code of Regulations Title 13, Chapter 9, Article 4.7§ 2445.1, Pleasurecraft warrants that each Pleasurecraft engine is designed, built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code, and is free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in Pleasurecraft’s application for certiﬁ cation.

3. Any part covered under this Warranty that is not scheduled for replacement as required maintenance, in the written instructions to be found within the Pleasurecraft Owners/Operators Manual, is warranted for the period of two (2) years. If the part fails during the period of warranty coverage, Pleasurecraft will repair or replace the defective part at any Pleasurecraft warranty station. The repair or replacement will be performed at no charge to the owner. Any such part repaired or replaced under this Warranty will be warranted for the remainder of the two (2) year period.

4. Any part covered under this Warranty that is scheduled only for regular inspection in the written instructions to be found within the Pleasurecraft Owners/Operators Manual, is warranted for the period of two (2) years. If the part fails during the period of warranty coverage, Pleasurecraft will repair or replace the defective part at any Pleasurecraft warranty station. The repair or replacement will be performed at no charge to the owner. Any such part repaired or replaced under this Warranty will be warranted for the remainder of the two (2) year period.

5. Any part covered under this Warranty that is scheduled for replacement as required maintenance in the written instructions to be found within the Pleasurecraft Owners/Operators Manual will be warranted for the period of time before the ﬁ rst scheduled replacement date for that part. If the part fails before the ﬁ rst scheduled replacement, Pleasurecraft will repair or replace the defective part at any Pleasurecraft warranty station. The repair or replacement will be performed at no charge to the owner. Any such part repaired or replaced under this Warranty will be warranted for the remainder of the period prior to the ﬁ rst scheduled replacement date for the part.

6. Replacement of any part under this Warranty with a Pleasurecraft supplied part, will not shorten nor extend the warranty period(s) stated in paragraphs one (1) thru four (4) above.

7. The engine owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective, emission-related warranted part, provided that such diagnostic work is performed at a Pleasurecraft warranty station.

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INTRODUCTION - 1

8. To insure prompt repair under this Warranty, Pleasurecraft will maintain a supply of warranted parts sufﬁ cient to meet the expected demand for such parts. Any replacement part may be used in the performance of any warranty maintenance or repairs and will be provided by Pleasurecraft without charge to the owner.

9. Parts covered under this Warranty are: spark plugs, spark advance/retard system, ignition coil and/or control module, ignition wires, PCV valve, oil ﬁ ller cap, intake valve(s), intake manifold, exhaust manifold, exhaust valve(s) hoses, clamps, ﬁ ttings, tubing, sealing gaskets or devices, and mounting hardware, pulleys, belts and idlers, temperature check, and valves and switches, and electronic controls.

10. Exclusions: The repair or replacement of any warranted part otherwise eligible for coverage under this Warranty may be excluded from such warranty coverage if Pleasurecraft demonstrates that the engine and/or part has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part.

11. Pleasurecraft original equipment parts are “identical in all material respects to that part as described in the engine manufacturer’s application for certiﬁ cation”. The use of any replacement parts not supplied by Pleasurecraft may not meet this requirement and will be grounds for disallowing a claim made under this Warranty. Pleasurecraft will not be liable under this Warranty or provide warranty coverage for product failures caused by parts other than Pleasurecraft original equipment parts.

12. If you have any questions regarding your warranty rights and responsibilities, or the location of Pleasurecraft warranty stations near you, you should contact Pleasurecraft at 1-803-345-0050.

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INTRODUCTION - 1

This Page Was

Intentionally

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INTRODUCTION - 1

SAFETY INFORMATION

“Safety Warnings” and additional information or instructions are used to alert the installer/operator of possible safety hazards in performing certain service or maintenance procedures incorrectly or carelessly. DANGERS and WARNINGS are accompanied by the international HAZARD symbol:

These “Safety Warnings” alone cannot eliminate the hazards that they signal. Strict compliance with these warning instructions while performing service and maintenance procedures, plus “common sense” operation, are major accident prevention measures.

REPLACEMENT PARTS

DANGER

Electrical, ignition and fuel system components are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize the possibility of ﬁ re or explosion hazard.

Use of replacement parts (i.e. automotive, after-market, etc.) in the electrical, ignition and fuel systems, which are not U.S. Coast Guard approved, could cause a ﬁ re or explosion hazard and should be avoided.

Always request that genuine PCM Engines replacement parts be used in any repairs or maintenance being performed on your engine(s).

SAFETY WARNINGS

DANGER

Signals serious damage, failure or breakdown of equipment; severe injury or high probability of death to the user if proper precautions are not taken. This signal word is applied in extreme situations

WARNING

Indicates a potential hazard which could result in personal injury.

CAUTION

Indicates a hazard which could result in damage to equipment.

IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily.

WARRANTY NOTICE: Indicates a possible warranty exclusion.

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BOATING RESPONSIBILITIES - 2

CARBON MONOXIDE HAZARD

DANGER

Carbon Monoxide (CO) is a colorless, odorless and tasteless gas. You cannot see it, smell it or taste it. Prolonged exposure to carbon monoxide can lead to unconsciousness, brain damage or death!

Carbon monoxide is produced when anything that contains carbon, such as gasoline, natural gas, oil, propane, coal or wood is burned. Carbon monoxide is commonly found in the exhaust of internal combustion engines (boat power plants, generators, etc.). In addition, open ﬂ ame devices like cooking ranges, heaters and charcoal grills also produce carbon monoxide.

Carbon monoxide accumulation, in and around boats is affected by vessel geometry; overall vessel design; closeness to other structures; wind direction; boat speed; and many other variables. In no way can this section cover all of the possible variables. Do not rely on this section as the exclusive listing of measures to prevent the accumulation of carbon monoxide.

To ﬁ nd out more about making boating safer, including how you can prevent carbon monoxide poisoning on recreational boats, contact:

National Marine Manufacturers Association

200 East Randolph Drive

Suite 5100

Chicago, IL 60601-6528

www.nmma.org

312-946-6200

United States Coast Guard

Ofﬁ ce of Boating Safety

CG Headquarters G-OPB-3

2100 Second Street SW Washington, DC 20593

www.uscgboating.org

202-267-0984

American Boat & Yacht Council, Inc.

3069 Solomon’s Island Road Edgewater, MD 21037-1416

www.abyc.com

410-956-1050

Consult your boat operators manual for detailed information on the inspection and/or maintenance of the exhaust system for your particular application. If an inspection reveals possible leaks, DO NOT operate your engine(s) until it can be serviced by a qualiﬁ ed technician.

Proper and adequate air circulation, around and throughout the boat, is absolutely necessary to aid in the prevention of carbon monoxide build-up. If you have any questions or concerns regarding the operation of your boat and carbon monoxide hazards, DO NOT operate your engines until you have contacted your boat manufacturer.

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BOATING RESPONSIBILITIES - 2

SAFE BOATING SUGGESTIONS

The nation’s waterways are becoming increasingly crowded and, in order to enjoy them safely, the operator should acquaint himself/herself with safe boating practices. Boating safely and seamanship courses are offered by the following national and state organizations:

• Power Squadrons

• Coast Guard Auxiliary

• Red Cross

• State, provincial or local agencies in charge of water safety enforcement

PCM Engines highly recommends that all power boat operators attend one of these courses. To help locate a course being offered near you, contact Boat U.S. Foundation’s toll-free national boating safety hotline, 1-800-336-BOAT, and in Virginia, 1-800-245-BOAT.

WATER WISDOM

The following are suggestions for safe operation of your boat to ensure the safety of yourself and your passengers:

• Know your boat’s loading and operating limitations. DO NOT OVERLOAD!

• Make periodic checks of safety equipment onboard.

• Do not consume alcoholic beverages or take illegal drugs when operating a boat. Some state laws apply to boats as well as motor vehicles.

• File a “ﬂ oat plan.” Let someone know your destination and your expected time of return.

• Monitor the weather. Know the signs of weather change and avoid severe weather and rough seas whenever possible.

• Follow the “Rules of the Road” when boating. Always be on the alert and watch out for “the other guy.”

• Plan and chart your course. Be aware of, and avoid, hazardous areas.

• Be sure your boat is equipped with the required safety equipment. Check with the Coast Guard and local government agencies as to the regulations and restrictions in your area. Contact your local Coast Guard Auxiliary and take advantage of their seasonal boat inspections.

The following is a list of suggested safety equipment and spare parts which may be useful in case of an emergency:

• Approved personal ﬂ otation devices (life jackets); one for each person on board.

• Approved throwable personal ﬂ otation device for man-overboard protection.

• Approved ﬁ re extinguishers

• Signal devices: ﬂ ares, spotlight, signal ﬂ ag and horn or whistle

• PCM Engines’ “Onboard Kit,” plus spare fuses, bulbs, batteries, etc. Tools necessary for minor repairs

• Spare propeller

• Anchor and anchor line

• First aid kit and ﬁ rst aid book

• Ship-to-shore radio, compass and chart of the area in which you are traveling

• Manual bilge pump and spare drain plugs

• Waterproof storage containers

OPERATION AND MAINTENANCE

It is the owner’s/operator’s responsibility to perform all safety checks before operating his/her boat. All lubrication and maintenance schedules must be adhered to assure optimum performance and dependability from your PCM engine. When service and maintenance are required, return to your authorized PCM Engine Dealer.

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BOATING RESPONSIBILITIES - 2

RULES OF THE ROAD

Channel Buoy Guide

The color of the paint is the only characteristic which has the same meaning on all buoys. Red buoys always indicate the starboard side of the channel from seaward. (Red Right Returning)

starboard side of the channel when returning from sea. It is conical shape, the color red and indicates even numbers. A nun buoy with red and green horizontal bands (top band red), and not numbered,

indicates an obstruction. The principal channel is to the left of the buoy when returning from sea.

2. Can Buoy: This buoy indicates the port side of the channel when returning from sea. It is cylindrical shape, the color green and indicates odd numbers. A can buoy with green and red horizontal bands (top

band green), and not numbered, indicates an obstruction. The principal channel is to the right of the buoy when returning from sea.

3. Lighted Buoy (RED): This buoy has a ﬂ ashing red light. It indicates the starboard side of the channel when returning from sea.

4. Lighted Buoy (GREEN): This buoy has a quick ﬂ ashing green light. It indicates the port side of the channel when returning from sea. The quick ﬂ ashing light indicates special caution required.

1. Nun Buoy: This buoy indicates the

Boat Capacity

• Load only to manufacturer’s speciﬁ cations

• Distribute load evenly; keep it low

• Passengers should only ride on the parts of the boat that are designed for that purpose

• If water is rough, carry fewer passengers

Observe the Rules of the Road

PORT (Left) - Leaving the harbor with green buoys to your right. STARBOARD (Right) - Entering the harbor with red buoys to your right.

Keep to Right

in narrow channels.

Boat being overtaken

has right of way.

Overtaking boat must

stay clear.

Yield to boats

approaching in

this area.

Know Your Horn Signals

1 Short Blast = Passing you on my port side 2 Short Blasts = Passing you on my starboard side 3 Short Blasts = I am going astern 5 Short Blasts = Danger

Always refer to the latest U.S. Coast Guard Navigation Rules CG-169

Keep An Alert Lookout For:

Bad weather, Swimmers, Other boats, Water skiers, Fisherman, Divers and/or any other obstructions

Small Craft

Winds up to

38 MPH

Gale Winds

38 - 54 MPH

Storm Winds over 55 MPH

Storm Warning Signals - Pennants (by day) Lights (by night)

Hurricane

Winds over

63 MPH

Keep Your Wake Under Control, particularly upon entering or leaving harbor areas. You are responsible for wake damage to other vessels and/or property.

Do Not Fool With Fuel

1/2 pint of gasoline = 15 sticks of dynamite

1. During fueling, moor boat properly; remove all passengers.

2. Keep all doors, hatches and ports closed.

3. Shut down all electronic gear; extinguish galley ﬁ res, pilot lights and smoking materials.

4. Do not overload tanks.

5. Keep ﬁ lling nozzles in contact with the ﬁ ll pipe to prevent sparks.

6. Secure the ﬁ ll cap tightly; wipe away any spillage.

7. Ventilate all components for a minimum of ﬁ ve minutes before starting engines.

8. Keep fuel lines and bilges clean.

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ENGINE IDENTIFICATION - 3

ENGINE IDENTIFICATION

When ordering service parts or obtaining information, always give the engine model and the serial number. This information can be found on the following decal.

MAKE MODEL SERIAL FIRING ORDER

THIS ENGINE CONFORMS TO ALL APPLICABLE U.S. GOVERNMENT STANDARDS FOR MARINE ENGINES IN EFFECT AT DATE OF MANUFACTURE.

LITTLE MOUNTAIN, SC 29075

Figure 3-1 Engine Identiﬁ cation Decal

OWNER IDENTIFICATION AND REGISTRATION INFORMATION

We suggest that you record the following information for quick reference when ordering parts or requesting service or warranty.

5.7L 350 c.i.d MULTIPORT FUEL INJECTION

FUELRECOMMENDATIONS Unleaded89 Octane (Minimum)

FUELPRESSURE 48-52@ Idle 53-57@ W.O.T.

ENGINEOIL RECOMMENDATIONS 15W-40Above 50degrees F

5W-30Below 50 degreesF

MARINEGEAR OIL RECOMMENDATIONS AllPCM, Warner andHurth Transmissions:Dextron III

Important!See yours ownersmanual toinsure that specificationsfor your enginehave not changedor beenommitted from thespecifications listed.

ENGINES

1. ENGINE SPECIFICATION DECAL

MAKE MODEL SERIAL FIRING ORDER

THIS ENGINE CONFORMS TO ALLAPPLICABLE U.S. GOVERNMENT STANDARDS FOR MARINE ENGINES IN EFFECT ATDATE OF MANUFACTURE.

LITTLE MOUNTAIN,SC 29075

MAXIMUMCONTINUOUS CRUISE: 3800RPM MAXIMUMENGINE SPEED (WOT):5000 RPM

ELECTRICALSPECIFICATIONS 12Volts -Negative Ground

IGNITIONTIMING @ 1000RPM 10degrees (Non-adjustable)

SPARKPLUG: Gap.060" FIRINGORDER: 18436572

ENGINEIDLE: 650-700 (Non-adjustable)

marineengines

HIGHWAY76 EAST

SERIALN

OILTYPE: DEXRONIII

LITTLEMOUNTAIN S.C.29075

PCM

MARINEPOWER

MODEL

RATIO

CHECKOIL LEVELDAILY OILCHANGE AFTERFIRST 25HOURS OF OPERATIONAND EVERY100 HOURSOR 12 MONTHS,WHICHEVER OCCURSFIRST. IMPORTANTNOTE: WARRANTYIS VOIDIF MAINTENANCEAND LUBRICATIONINSTRUCTIONS PERPCM MANUALARE NOTFOLLOWED.

3. TRANSMISSION IDENTIFICATION PLATE

2. ENGINE IDENTIFICATION DECAL

Figure 3-2 Engine Identiﬁ cation Tag Locations (5.0/5.7L)

PORT STARBOARD

Engine Model Number:

Serial Number(s):

Gear Model Number:

Serial Number(s):

Boat Make:

Boat Model:

Hull Serial Number:

Propeller Size:

Ignition Key Number:

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ENGINE IDENTIFICATION - 3

PCM

2003 MODEL IDENTIFICATION / ADVISORY

MODEL P X L A P R R 123 M SERIAL 430000

1st Space: MANUFACTURER P - Pleasurecraft Marine

2nd Space: FACT OR Y FRESHWATER / CLOSED COOLING X-Freshwater Cooled

(Space Omitted If Raw Water Cooled )

3rd Space: ENGINE ROTATION

L - Rotation, Left-Hand from Rear R - Rotation, Right-Hand from Rear

4th Space: ENGINE TYPE A = 5.7L (350 CID HO) (GM) Q = 6.0L (364 CID) (GM) G = 5.0L (305 CID STD) (GM) X = 8.1L (496 CID STD) (GM) Z = 8.1L (496 CID HO) (GM)

8th 9th 10th Spaces: DRIVE GEAR RATIO OR REDUCTION The drive gear ratio will appear in these spaces which identiﬁ es the production gear specs. The example gear number shown is a (1.23:1). If the gear being identiﬁ ed does not have 3 digits, a “0” will appear in 10th space. Example: ( 1.0:1 ) will appear as 100 ( 1.5:1 ) will appear as 150

*MODELS ENDING WITH “000000” IN

PLACE OF DRIVE I.D. ARE BOBTAIL ENGINES.

Space: IGNITION / FUEL TYPE USED

D - DISTRIBUTOR (Carb) E - THROTTLE BODY INJECTION M - MULTI-PORT FUEL INJECTION

5th Space: DRIVE MANUFACTURER P - Pleasurecraft W - Borg-Warner

V - Velvet Drive (cast iron units. Specify 71c or 72c) H - Hurth

6th Space: DRIVE FUNCTION / APPLICATION

R - Reverse / Reduction V - Vee Drive / Reversed Risers F - Full Reversing

Space: PROPELLER SHAFT ROTATION

L - Left-Hand Rotation R - Right-Hand Rotation

*SERIAL NUMBER I.D.*

1st DIGIT INDICATES DECADE ENGINE WAS MANUFACTURED ( 3 = 1990, 4 = 2000, 5 = 2010 ) 2nd DIGIT INDICATES YEAR ENGINE WAS MANUFACTURED.

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ELECTRONIC FUEL INJECTION INFORMATION - 4

ELECTRONIC FUEL INJECTION SYSTEM

The PCM engines covered in this manual are equipped with an Electronic Fuel Injection (EFI) system, which allows precise control of fuel and spark delivery. The fuel system components of the EFI system are:

• The electric fuel pump

• The throttle body assembly

• The fuel injectors The fuel injection system is controlled by an Electronic

Control Module (ECM). The ECM is the decision center of the system. The ECM constantly monitors information from various sensors on the engine, and electronically processes the information, in order to control ignition timing and fuel delivery for optimum performance and fuel economy. The ECM incorporates an engine overspeed protection, calibrated to a speciﬁ c RPM, to prevent engine damage from over-revving.

The sensors that the ECM monitors are:

• Engine Coolant Temperature (ECT) Sensor

• Throttle Position (TP) Sensor

• Manifold Absolute Pressure (MAP) Sensor

• Knock Sensor (KS) System

• Crankshaft Positioning (CKP) Sensor

• Camshaft Positioning (CMP) Sensor

• Intake Air Temperature (IAT) Sensor

POWER REDUCTION MODE

The ECM monitors engine oil pressure and engine coolant temperature whenever the engine is running. If either one of these inputs indicate an abnormal reading, the system will go into “Power Reduction” mode, followed by the illumination of an indicator lamp and/or sounding of the warning buzzer (if equipped). This is a feature that will help protect the engine during an overtemp or low oil pressure condition.

When in “Power Reduction” mode, the ECM will allow normal engine performance up to 2000 RPM. Above 2000 RPM, the ECM allows fuel delivery through only half of the fuel injectors. Once the RPM is brought down below 1200 RPM, normal engine operation is restored until the RPM exceeds 2000 RPM. The feature allows maneuverability of the boat while removing the possibility of high engine speed operation until the problem is corrected.

NOTICE: If it is not possible to safely shut off the engine, return the engine to idle speed. Once returned to idle, the ECM will allow the engine to operate normally below 2000 RPM.

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OPERATING INSTRUCTIONS - 5

ENGINE ALARM SYSTEM (IF EQUIPPED)

The PCM engine electronic system is programmed to control the engine alarm system. This system utilizes an audible alarm and/or optional indicator lamps to warn the operator of possible engine problems, and that the engine have entered the “Power Reduction” mode as covered earlier in this manual.

The alarm has a “self” checking feature programmed into the system. This feature will sound the alarm for two short pulses upon initial start-up of the engine.

If the alarm sounds during operation, immediately throttle back to idle speed. Observe the indicator lamps to locate the problem circuit. The engine should be shut off to prevent damage to the engine.

NOTICE: Some boat builders may install their own alarm system. It is recommended that the boat owner check with his or her boat dealer for an explanation of the particular alarm system upon initial delivery.

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INSTRUMENTATION

Boat manufacturers install many different types of instrumentation on boats. Become familiar with the instrumentation on your boat and be aware of abnormal operating conditions. The following is a brief explanation of typical instrumentation found on most boats:

1. Tachometer - indicates the engine RPM (revolutions per minute)

2. Engine Synchronizer (twin engines only)

3. Water Temperature Gauge - indicates the engine coolant temperature

4. Oil Pressure Gauge - indicates the engine oil pressure

5. Voltmeter - indicates the battery voltage and charging system voltage

6. Hour Meter - indicates the engine operating time

OPERATING INSTRUCTIONS - 5

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OPERATING INSTRUCTIONS - 5

STARTING ENGINE (FUEL INJECTED ENGINES)

WARNING

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

IMPORTANT: Do not start the engine without water being supplied to the sea water pick-up pump or sea-water pump impeller will be damaged, and subsequent overheating damage to the engine may result.

IMPORTANT: The following items should be checked before starting the engine, and each time the boat is operated:

• Fuel system for any signs of leakage

• Operation of remote controls and steering

• Engine and transmission oil levels

• Fuel tank levels

• Exhaust system for leaks and tightness of the clamps

Check for signs of external leaks

Figure 5-2A Water Leaks

After performing the initial safety checks, proceed as follows to start the engine:

1. Turn the battery switch ON (if equipped).

2. Open the fuel valve.

3. Open the seacock.

4. Place the remote control in Neutral position. The transmission is equipped with a neutral safety switch, which will not allow the starter motor to operate unless the transmission is in neutral.

Check for signs of external leaks

• Battery connections and water level in battery cells

• Accessory drive belt(s)

• Cooling system for leaks. If equipped with fresh water cooling, check coolant level in recovery bottle. Check for signs of water leaks at the exhaust manifolds, risers and elbows (Figure 5-2A). If the water is leaking externally, it is possible that the water is also leaking internally. This could result in internal engine damage. It is very important to service these maintenance items as soon as a problem is indicated.

5. Do not pump or open the throttle when starting the engine (Figure 5-1). The ECM will automatically regulate the fuel and control desired idle speed.

6. Turn the ignition key to the start position. When the engine starts, release the key.

NOTICE: Engine idle speed is controlled by the ECM and is based on the operating temperature of the engine. Upon initial start-up, engine RPM will be slightly higher and will automatically decrease as the engine operating temperature increases.

7. In the event the engine becomes ﬂ ooded, move the throttle lever to a 100% open position (Figure 5-1). At this throttle position, the ECM will command the injectors to deliver no fuel during engine cranking. When the engine starts, return the throttle lever back to the idle position.

IMPORTANT: If the engine fails to start within 20-30 seconds, turn the ignition key to the OFF position and allow 2 minutes for the starter motor to cool off before attempting to restart the engine.

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CLEAR FLOOD

(100%)

STARTING

OR IDLE

POSITION

OPERATING INSTRUCTIONS - 5

SHIFTING TRANSMISSION

CAUTION

Never shift the transmission into or out of gear unless the throttle is at the idle position. Shifting the transmission above 1000 RPM can severely damage the boat, transmission and engine.

1. Set the throttle lever at the idle position.

FULL

THROTTLE

(WOT)

Figure 5-1 Throttle Position Setting

NOTICE: If engine still fails to start, contact your PCM Engines Dealer for service.

8. Check engine oil pressure immediately after the engine starts. If oil pressure is not within speciﬁ cations (see Engine Speciﬁ cations), immediately stop the engine and determine the cause.

9. Check voltmeter for proper charging system operation.

2. Move the transmission lever completely forward to shift into Forward gear.

3. Move the transmission lever completely backward to shift into Reverse gear.

4. Move the transmission lever to the center detent position to shift into Neutral.

NEUTRAL

REVERSE

GEAR

FORWARD

GEAR

10. Check the engine and transmission for fuel, oil, water and exhaust leaks.

11. Allow the engine to reach normal operating temperature. Check the temperature gauge to ensure the engine is operating within the normal temperature range. If the temperature is abnormally high, stop the engine immediately and determine the cause.

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Figure 5-2 Shift Control

OPERATING INSTRUCTIONS - 5

STOPPING ENGINE

When returning to the dock, or whenever stopping the engine, bring the throttle back to the idle position. After the engine reaches idle speed, turn the ignition key to the OFF position.

Before stopping the engine after extended high speed operation, allow the engine to idle at 1200 RPM for 3 to 5 minutes to allow the engine to cool down before shutting off the ignition.

After stopping the engine, complete the following:

1. Turn the battery switch OFF, if equipped.

2. Close the fuel valve.

3. Close the seacock.

4. Flush the cooling system if in a salt water area.

FREEZING TEMPERATURE OPERATION

If the possibility of freezing exists, the cooling system must be protected after the engine is shut off to prevent freeze damage to the engine. Refer to OUT-OFSEASON STORAGE for draining instructions.

OPERATION IN HIGH DEBRIS AREAS

If the boat is to be operated in high debris areas, a sea strainer should be installed in the water inlet hose to prevent debris from entering the cooling system. The strainer used must be of sufﬁ cient size to allow an adequate supply of water for cooling the engine. A minimum of 30 gallons per minute (114 liters per minute) ﬂ ow rate is required.

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CONDITIONS AFFECTING OPERATION - 6

TRIM AND WEIGHT DISTRIBUTION

Trimming of the boat and positioning of the weight (gear and passengers) inside the boat has the following effects on handling:

• Trimming the bow up or shifting weight to the stern (rear).

− Normally used for cruising (running) with a choppy wave condition (following sea) for running at full speed

− Will generally increase speed and engine RPM

− Will cause the bow to bounce in rough water

− In extreme, may cause the boat to porpoise

− When coming off plane, it increases the chances of following wave splashing into the stern of the boat

• Trimming the bow down or shifting the weight to the bow (front)

BOAT BOTTOM

To ensure maximum engine performance, fuel economy and boat speed, the bottom of your boat must be kept clean and free of marine growth and barnacles. Marine vegetation may accumulate when the boat is docked and should be removed before operation. If the boat is docked for long periods of time, the water inlets may become clogged with growth and will cause the engine to overheat.

In most areas, it is advisable to coat the boat bottom with antifouling paint to prevent the build-up of marine growth. Contact your dealer for advice on these requirements in your area.

− Normally used for cruising (running) against a choppy wave condition, acceleration onto plane and operating at slow planing speeds

− Will improve rough water ride and handling

− In extreme, may cause the boat to bow steer (veer back and forth with little control)

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CONDITIONS AFFECTING OPERATION - 6

PROPELLER SELECTION

Best all-around performance and maximum engine life is achieved when the engine is propped to run near the top of (but within) the recommended full throttle RPM range with a normal load. See ENGINE SPECIFICATIONS for rated full throttle RPM for your model engine.

Generally, gross weight (total weight of the entire boat, including full fuel and water, optional equipment, passengers and other miscellaneous gear) is one of the major factors and should be one of the primary considerations when selecting a propeller. Other factors to take into consideration are as follows:

• Warmer weather and higher humidity will cause an RPM loss.

• Operating the boat in a higher elevation will cause an RPM loss.

• Operating the boat with an increased load will cause an RPM loss (additional equipment, passengers, etc.).

If full throttle RPM is above or below the recommended range as stated in ENGINE SPECIFICATIONS, the propeller must be changed to prevent loss of performance. A one-inch change in either the pitch or diameter of a given propeller will generally change engine RPM by 150 to 250 RPM.

ENGINE RPM CHART

Minimum Model Full Load Maximum

MP 5.0L 4400 5000 MP 5.7L 4400 5000 MP 6.0L 5000 5200 MP 8.1L (STD) 4200 4600 MP 8.1L (HO) 4800 5000

CAUTION

Prolonged WOT operation will shorten the life of your engine and could cause premature engine failure. See NORMAL CRUISING SPEEDS in SPECIFICATIONS. Problems caused by WOT operation are considered abuse and are not covered under the PCM Warranty.

NOTICE: These engines incorporate an RPM “REV LIMIT” in order to prevent the engine from over-revving.

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ENGINE BREAK-IN PERIOD - 7

WARNING

Use this procedure ONLY when conditions are such that it can be done in complete safety.

The break-in period of your engine is the ﬁ rst 25 hours of operation. Proper engine break-in is essential to achieve maximum performance, longevity and minimum oil consumption. During the break-in period, the following operation guidelines must be adhered to:

• After the engine is thoroughly warmed up, and the boat is underway, open the throttle to wide open throttle until maximum RPM is reached. DO NOT EXCEED MAXIMUM RPM. (RPM should cease climbing after 10 to 20 seconds).

CAUTION

DO NOT operate at full throttle in neutral at any time, or at sustained full throttle during the ﬁ rst 5 hours of operation. Thereafter, use sustained wide open throttle in the event of an emergency.

The engine oil level should be checked often and oil added when necessary. It must be understood that every internal combustion engine will use a certain amount of oil during operation to act as a lubricating and cooling agent, especially during the break-in period. Oil consumption should decrease and become stabilized after approximately 100 hours of operation.

At the end of your 25-hour break-in period, contact your dealer and have the recommended 25-hour inspection done.

NOTICE: PCM Engines assumes no responsibility for the costs related to the 25-hour inspection. This is the owner’s responsibility.

• Reduce the throttle to 2800 - 3000 RPM, and cruise at or below this speed for 1/2 hour. Reduce the speed to idle. Go to wide open throttle until maximum RPM is reached and operate for approximately 1 minute. Reduce throttle to 2800-3000 RPM and operate for a few minutes. (Bringing the engine speed from idle to wide open throttle will load the engine and assist in seating the piston rings). This cycle can be repeated from time to time during the ﬁ rst 5 hours of operation, but wide open throttle should not be sustained for more than 1 minute.

• During the early part of the break in period, the correct propeller selection can be conﬁ rmed. (With a normal load aboard, the engine’s RPM should reach, but not exceed, the maximum RPM as listed in the speciﬁ cations section).

• During the break in, all gauges should be watched carefully, and the speed should be reduced if abnormal readings become evident.

CAUTION

DO NOT attempt to break in any engine by prolong idling, or running at the dock.

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25-HOUR ENGINE INSPECTION - 8

After the ﬁ rst 25 hours of operation, it is recommended that the engine be given an inspection. Your boat dealer or a PCM servicing dealer should be contacted to perform the necessary checks and adjustments to ensure the proper engine performance. The following maintenance should be performed:

• Change the engine oil and ﬁ lter.

• Check and clean the primary fuel ﬁ lter

• Check the engine alignment.

• Inspect the accessory drive belt(s) and check the tension.

• Check all the ﬂ uid levels.

• Check the throttle and the shift cable adjustments and check for freedom of movement.

• Cooling System - Inspect all the hoses for leaks, damage and deterioration. Check all the hose clamps for adequate tightness.

• Exhaust System - Inspect the entire exhaust system for leaks, damage and deterioration. Check all the hose clamps for adequate tightness.

• Battery - Check the electrolyte level and speciﬁ c gravity. Inspect the case for damage. Check the battery cables and connections.

• Engine Assembly - Check for loose, missing or damaged parts. Pay close attention to engine mounts, starter and alternator mounting fasteners.

NOTICE: PCM Engines assumes no responsibility for the costs related to the 25-hour inspection. This is the owner’s responsibility.

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FUEL REQUIREMENTS - 9

GASOLINE REQUIREMENTS

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 PCM 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

UNLEADED

UNL

ADED

REGULAR

MINIMUM OCTANE RATING

R+M/2METHOD

GASOLINE CONTAINING ALCOHOL

Gasoline containing alcohol, either ethanol (ethyl alcohol) or methanol (methyl alcohol) is not recommended for use in your engine. Gasoline containing alcohol will attract and hold moisture and may cause the following:

• Hard starting and operating difﬁ culties (vapor lock, low speed stalling)

• Corrosion of metal parts

• Excessive wear and damage to internal engine parts

• Fuel permeation through ﬂ exible fuel lines

• Deterioration of some nonmetallic materials The adverse effects of alcohol are more severe with

methanol and are worse with increasing alcohol content. If gasoline containing alcohol is used, or if the presence

of alcohol is uncertain, more frequent inspections of the complete fuel system are required. Any sign of fuel leakage or deterioration must be repaired immediately before further engine operation.

Figure 9-1 Fuel Requirements

NOTICE: Most PCM Fuel Injected engines are calibrated to operate on 87 octane fuel and maximum performance is obtained when using this fuel. The use of higher octane fuels in these engines, besides added operating costs, can cause temporary performance loss. Therefore, the use of these fuels is not recommended.

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 PCM Engine service technician.

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.

NOTICE: Some gasolines contain an octane-enhancing additive called methylcyclopentadlenyl manganese tricarbonyl (MMT), and they should not be used. These fuels may reduce spark plug life, and engine performance may be effected.

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OIL REQUIREMENTS - 10

ENGINE OIL RECOMMENDATIONS

Use of Supplemental Additives

Engine oils meeting PCM Engines’ recommendations already contain a balanced additive treatment. The use of supplemental additives which are added to the engine oil by the customer are unnecessary and may be harmful. PCM Engines does not review, approve or recommend such products.

Synthetic Oils

Synthetic engine oils are not recommended for use in PCM Engines. Synthetics may offer advantages in cold temperature pumpability and high temperature oxidation-resistance. However, synthetic oils have not proven to provide operational or economic beneﬁ ts over conventional petroleum-based oils in PCM Engines. Their use does not permit the extension of oil change intervals.

Engine Oil Requirements

The following chart shows the recommended oil viscosity for various ambient temperature ranges:

Prevailing Ambient Recommended A.P.I. Temperature Classiﬁ cation & Viscosity

Above 50˚F SAE 15W-40 “SJ”

Below 50˚F SAE 5W-30 “SJ”

WARRANTY NOTICE: PCM Engines reserves the right to refuse warranty on part(s) and/or engine(s) damaged by using improper fuels and engine oils.

Oil Change Intervals (Common)

Crankcase oil and oil ﬁ lter change - Recommended intervals:

• Initial oil change - 1st 60 days or 25 hours of operation, whichever occurs ﬁ rst

• Regular oil changes - Every 50 hours of operation or 120 days, whichever occurs ﬁ rst

TRANSMISSION AND “V”-DRIVE OIL REQUIREMENTS

Recommended A.P.I. Transmission Classiﬁ cation and and “V” Drive Viscosity

PCM Dexron III Automatic Transmissions Transmission Fluid (ATF) or equivalent

Walters “V”-Drive SAE 30

Dexron III Automatic All Hurth Gear Transmission Fluid (ATF) Transmissions or equivalent

IMPORTANT: The use of oils which contain “solid” additives, non-detergent oils or low quality oils speciﬁ cally are not recommended.

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ENGINE MAINTENANCE

Refer to the MAINTENANCE SCHEDULE for a complete listing of required maintenance and the frequency at which it should be performed. Some procedures may be performed by the owner/operator while others should be performed by an authorized PCM Engines Dealer. Before performing any maintenance or repair procedure not covered in this manual, it is strongly recommended that a PCM Engines repair manual be purchased and read thoroughly.

CHECKING FLUID LEVELS

Engine Crankcase Oil

ENGINE MAINTENANCE - 11

CAUTION

Do not overﬁ ll engine crankcase with oil, as excess oil will be splashed by reciprocating engine parts onto the cylinder walls in greater quantity than the rings can control. The oil, subsequently, will be drawn into the combustion chamber and burned. Continuous operation under these conditions can cause carbon to form on combustion chamber surfaces, which will adversely affect engine performance and may lead to premature engine failure. Splashing or agitation of oil also may cause it to become aerated, which will affect the oil pressure, and may result in internal engine damage from lack of lubrication.

1. Stop the engine if running. Allow approximately 5 minutes for the oil to drain back into the oil pan.

2. Remove the dipstick, wipe it clean, and reinstall it fully into the dipstick tube.

3. Remove the dipstick and observe the oil level. The oil level must be between the “FULL” and “ADD” marks. If the oil level is below the “ADD” mark, add speciﬁ ed oil to bring the level up to, but not over, the “FULL” mark on the dipstick. (Figure 11-1).

ENGINE OIL

DIPSTICK

OPERATING

RANGE

FULL MARK

ADD MARK

Figure 11-1 Engine Oil Dipstick (Typical)

DIPSTICK

WARNING

The machinery space must be closed anytime the engine is running to prevent injury to you or others on board. Never operate the engine with the engine machinery space open while someone is in the machinery space, either closed or open. Never open the machinery space unless the engine is shut off and the engines rotating parts are stationary. Rotating machinery can cause injury and even death if an accident should occur. Extreme care must be exercised if a problem exists that requires operation of the engine with the machinery space open. IT

IS RECOMMENDED THAT UNCOVERED ENGINE OPERATION BE ATTEMPTED BY TRAINED AND QUALIFIED SERVICE PERSONNEL ONLY.

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ENGINE MAINTENANCE - 11

Transmission Fluid

CAUTION

PCM Engines uses marine transmissions supplied by several manufacturers. The maintenance requirements can be different between these manufacturers. It is important that you refer to the operation and maintenance manual supplied by the transmission manufacturer before you attempt to perform maintenance on your own. If no maintenance manual is available, PCM Engines recommends that you contact your dealer service department for any required maintenance or service instructions.

PCM Transmissions

1. Engine must be running at operating temperature.

2. Shift at least once into forward, once in reverse, then back to neutral.

3. With the engine running, and the prop shaft not turning, install the dipstick in all the way.

4. Remove the dipstick and check the ﬂ uid level. The dipstick should read FULL.

5. If the ﬂ uid level is low, add in small increments until the FULL mark is reached.

6. It is normal, after the engine is turned OFF, for the level to read above the FULL mark.

Hurth Transmission

WARNING

Do not attempt to remove the transmission dipstick while the engine is running. Hot transmission ﬂ uid could be sprayed from the dipstick hole.

1. Remove the dipstick by turning the T-handle counterclockwise. Observe the ﬂ uid level. Replace the dipstick and tighten securely.

2. Operate the engine until the engine and the transmission reach operating temperature.

3. Stop the engine and quickly check the ﬂ uid level to minimize the drain-back from the oil cooler. Remove the dipstick by turning the T-handle counterclockwise. Observe the ﬂ uid level.

4. The ﬂ uid level should be at the “FULL” or “MAX” mark. If low, add the speciﬁ ed ﬂ uid through the dipstick tube. Repeat checking procedures as required until the ﬂ uid level is at the “FULL” or “MAX” mark.

5. Replace the dipstick and tighten securely.

HURTH TRANSMISSION

SHIFT LEVER

PCM 1.23:1 TRANSMISSION

SHIFT LEVER

DIPSTICK

FULL MARK

Figure 11-2 Transmission Dipstick and Location

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DIPSTICK

MAX

MIN.

Figure 11-2A Transmission Dipstick and Location

ENGINE MAINTENANCE - 11

LUBRICATION

Throttle Cable

Lubricate pivot points and exposed cable (Figure 11-3) with SAE 30W-30 engine oil.

BALL JOINT

CABLE

CLIP

LUBRICATION

POINTS

Shift Cable

Lubricate pivot points and exposed cable (Figure 11-4) with SAE 30W-30 engine oil.

LUBRICATION

POINTS

Figure 11-4 Typical Shift Cable

Figure 11-3 Typical Throttle Cable

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ENGINE MAINTENANCE - 11

ELECTRICAL SYSTEM CIRCUIT BREAKER

Main Circuit Breaker

PCM engines are equipped with a circuit breaker which provides electrical overload protection for both engine and instrumentation wiring and components. Should an electrical overload occur, the circuit breaker will open and prevent electrical current ﬂ ow.

When this circuit breaker opens, the cause for the high current draw must be found and corrected. The circuit breaker can be reset by pushing the “Reset” button IN after waiting a few minutes. If the cause of the overload cannot be found, disconnect all accessories which are connected to the main wire harness.

If resetting is still not possible, check the battery and alternator connections and all other harness connectors on the main harness. Check for loose or disconnected lead wires and shorted circuits.

ELECTRICAL SYSTEM FUSES

PCM engines utilizes fuses to control the fuel pump, ECM and fuel injectors. The fuse block is mounted to a bracket near the exhaust elbow under a weather-tight cover.

FUSE BLOCK

CIRCUIT

BREAKER

Figure 11-5 Typical Electrical System Circuit Breaker

and Fuses

IGNITION FUSE

If the engine will not crank when the ignition key is turned to the START position, ﬁ rst check that the shift lever is in neutral position. If the main circuit breaker is not tripped, check for blown ignition fuse. The ignition fuse may be located on the instrument panel, the fuse holder block or as part of the instrument wiring harness. Check the wiring diagrams supplied from the boat manufacturer for the exact location.

ELECTRICAL SYSTEM WIRING AND CONNECTORS

The electrical system wiring and connectors should be checked periodically for loose or dirty connections and damaged wiring. If electrical components or wiring show signs of corrosion, deterioration or damage, consult a PCM Engine dealer to make necessary repairs.

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ENGINE MAINTENANCE - 11

BATTERY

WARNING

Battery electrolyte is a corrosive acid and should be handled with care. If electrolyte is spilled or splashed on any part of the body, IMMEDIATELY ﬂ ush the exposed area with liberal amounts of water and obtain medical aid as soon as possible. Safety glasses and rubber gloves are recommended when handling batteries or ﬁ lling with electrolyte.

WARNING

Hydrogen gases that escape from the battery when charging are highly explosive. Do not use jumper cables and a booster battery to start the engine. Do not recharge a weak battery in the boat. Remove the battery from the boat and recharge in a well ventilated area away from fuel vapors, sparks and open ﬂ ames.

Follow maintenance instructions and warnings as supplied by the battery manufacturer. If this information is not available, follow these guidelines for the proper battery care.

• Do not operate the engine with an open in the battery circuit, as this may cause damage to the alternator. Make sure that all connections are clean and secure.

• When removing the battery cables, always remove negative (-) cable ﬁ rst, and then remove the positive (+) cable. When installing battery cables, install the positive (+) cable ﬁ rst, then install the negative (-) cable.

• Periodically check the battery for signs of corrosion, frayed battery leads or cracked case. Repair or replace as necessary.

• Periodically check the electrolyte level. Add distilled water to bring up to the proper levels.

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ENGINE MAINTENANCE - 11

FRESH-WATER COOLING SYSTEM SACRIFICIAL ZINC ANODE

Located in the raw water side of the heat exchanger is a zinc anode which is marked by a decal. To check, remove the plug and visually check the condition of the zinc rod. The length of the zinc rod when new is approximately 1.5 inches. If more than one half of the zinc is gone, replace with a new zinc anode.

Different geographic locations and water make-up can result in either high or low sacriﬁ cial requirements. A high rate of zinc anode consumption should also alert the owner to a possibility of an improperly wired boat accessory, which would require complete checking by qualiﬁ ed service personnel.

HEAT EXCHANGER

PROTECTIVE ANODE

Remove and checkcondition of zinc pencil every 30 days.Replace if more than 50%

ZINC

missing with CrusaderPart #10972.

P/N23627

ANODE

Figure 11-6 Zinc Anode Location F.W.C. Heat

Exchanger (8.1L)

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CHECKING COOLANT LEVEL

WARNING

Do not remove cooling system ﬁ ller cap when the engine is hot. Allow the engine to cool and then remove the pressure cap slowly, allowing the pressure to vent. Hot coolant, under pressure, may discharge violently and cause severe burns.

Coolant Recovery Reservoir

The “see-through” plastic reservoir is connected to the heat exchanger by a small hose. The recovery bottle collects coolant that expands with rising temperature, and would otherwise overﬂ ow from the system. Coolant level should be at or slightly above the “ADD” mark on the bottle when the system is cold. Coolant should be added ONLY to the reservoir when the system cools.

Coolant Filler Neck

ENGINE MAINTENANCE - 11

COOLANT

RECOVERY

TANK

Figure 11-7 Checking Coolant Level (8.1L)

PRESSURE

CAP

Periodically, on a cool engine, remove the pressure cap from the ﬁ ller neck to ensure the coolant recovery system is functioning properly. Coolant must be at the top of the ﬁ ller neck. If coolant is low, check the gasket in the cap for damage. Replace if necessary. Inspect the coolant recovery system for leaks.

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ENGINE MAINTENANCE - 11

FLUSHING COOLING SYSTEM - SEA-WATER SECTION

To prevent silt and/or salt build-up in the cooling system (fresh or raw-water cooled), ﬂ ush the sea-water section of the cooling system with fresh water at speciﬁ ed intervals. Close seacock (if applicable) before removing inlet hose.

CAUTION

Do not operate the engine without sufﬁ cient amount of water being supplied to the sea-water pump. The sea-water pump impeller may be damaged and subsequent overheating damage may result.

CAUTION

Do not run the engine above 1500 RPM when ﬂ ushing. Suction created by the sea-water pump may collapse the ﬂ ushing hose, causing the engine to overheat. Watch the temperature gauge while ﬂ ushing to ensure the engine does not overheat.

ATTACH

FLUSHING

ADAPTER

HERE

Figure 11-8 Typical Sea-Water Inlet

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ENGINE MAINTENANCE - 11

TESTING COOLANT FOR ALKALINITY

It is recommended that the coolant in the fresh-water section be tested each year for alkalinity. Coolant that is not alkaline has lost the effectiveness of its rust inhibitors, which can lead to internal corrosion and cooling system problems. It is recommended to replace the standard ethylene glycol coolant in the system every two years to prevent a build-up of harmful chemicals within the fresh-water system.

1. Obtain red litmus paper from a local supplier (drugstore, laboratory, etc.).

2. Remove the pressure cap from the coolant ﬁ ller neck and insert one end of the litmus paper into he coolant.

3. If red litmus paper turns blue, coolant is alkaline and does not need to be replaced. If the litmus paper remains red, the coolant is not alkaline and must be replaced.

DRAINING FRESH-WATER COOLING SYSTEM

NOTICE: To protect the environment, dispose of coolant

properly. Check your local restrictions for proper disposal instructions of removed coolant.

NOTICE: Refer to cooling system water ﬂ ow diagrams for drain locations.

1. Remove the following drain plugs to drain coolant from the fresh-water cooling system:

− Drain plug on heat exchanger

− Remove the large hose from the engine block water circulating pump, or drain plug on circulation pump

− Drain plugs on the cylinder block (one on each side)

2. Remove the following drain plugs to raw water from the fresh-water cooling system:

− Drain plug on oil cooler

− Drain plug on heat exchanger

− Drain plug on the bottom of each exhaust manifold

3. After system has drained completely, coat all the drain plugs with PerfectSeal (or equivalent) and reinstall in the proper locations. Reinstall the hose(s) on the water circulating pump and tighten the clamps securely.

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ENGINE MAINTENANCE - 11

FILLING FRESH-WATER COOLING SYSTEM

A new extended life engine coolant known as DEXCOOL™ is used in your engine(s). It is imperative to note the following about DEX-COOL™ engine coolant:

• IT IS PINK IN COLOR TO DISTINGUISH IT FROM CONVENTIONAL COOLANT.

• THE SERVICE CHANGE INTERVAL ON ENGINES BUILT WITH DEX-COOL™ IS 5 YEARS.

• TO MAINTAIN FULL CORROSION PROTECTION DURABILITY, DEX-COOL™ MUST NOT BE MIXED WITH CONVENTIONAL (CONTAINING SILICATE) ENGINE COOLANTS.

• DEX-COOL™ IS AN ETHYLENE GLYCOL BASED PRODUCT, THEREFORE, BOIL AND FREEZE PROTECTION ARE MEASURED IN THE SAME FASHION AS CONVENTIONAL COOLANTS.

TO FULLY REALIZE ITS MANY ADVANTAGES, DEX-COOL™ MUST NEVER BE MIXED WITH CONVENTIONAL COOLANTS.

DEX-COOL™ can become contaminated by inadvertently topping-off with conventional coolant, adding conventional coolant to the system or even if ﬁ ll/drain containers are shared between coolants. If contamination occurs, the cooling system must be immediately drained and ﬂ ushed, and reﬁ lled with DEXCOOL™. No short-term damage will occur, however, the service interval will be reduced from 5 years to 2 years.

3. Start the engine and operate at idle speed (800-1000 RPM) to purge any air from the system. When the system is full, install the pressure cap.

FILL

RISER

ADD

Figure 11-9 F.W.C. Fill Riser Location (8.1L)

ANTIFREEZE

SOLUTION

The fresh-water cooling side of the cooling system must be ﬁ lled with a 50/50 mixture of DEX-COOL™ (or equivalent, which meets GM6277M) extended life antifreeze and water solution.

IMPORTANT: More than 50% antifreeze solution can contribute to an overheating condition.

IMPORTANT: If the engine is being placed in winter storage, the fresh-water cooling section must be ﬁ lled with a correct type of coolant and water solution, properly mixed, to protect the engine to the lowest temperature to

which it will be exposed.

1. Make sure that all drain plugs are properly installed.

2. Remove the pressure cap. Fill the system with antifreeze solution until the system is ﬁ lled. See ENGINE FLUID CAPACITIES for system capacities.

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ADD

Figure 11-10 Filling F.W.C. System (8.1L)

ANTIFREEZE

SOLUTION

Figure 11-10A Filling F.W.C. System (6.0L)

ENGINE MAINTENANCE - 11

CLEANING SEA-WATER SECTION OF HEAT EXCHANGER - FRESH-WATER COOLED MODELS ONLY

The sea-water section of the heat exchanger should be cleaned whenever there is a noticeable decrease in cooling efﬁ ciency. You may use the following procedure for cleaning, or, if the build-up of scale and mineral deposits is heavy, it is recommended that the heat exchanger be removed and taken to a repair facility to be

boiled out (such as a radiator repair facility).

1. Remove the bolts securing the heat exchanger end plates. Remove the end plates and gaskets.

2. Clean the water passages in the heat exchanger by inserting a suitable-size wire brush into each passage. Use compressed air to blow out loose particles.

3. Clean the gasket surfaces on the end plates and the heat exchanger. Apply PerfectSeal to both sides of the new gaskets. Install the end plates and the new gaskets onto the heat exchanger. Install the bolts and tighten securely.

HEAT

EXCHANGER

PLATE

COOLANT

DRAIN PLUG

RAW WATER

DRAIN PLUG

GASKET

BOLT

Figure 11-11 Heat Exchanger and End Plate Removal

(Typical)

4. Start the engine and inspect for leaks.

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ENGINE MAINTENANCE - 11

FUEL SYSTEM DESCRIPTION Fuel Control Cell (FCC) Fuel System

The Fuel Control Cell (FCC) eliminates vapor lock and

WARNING

Extreme caution must be exercised when servicing the fuel system and/or replacing fuel ﬁ lter. Gasoline is extremely ﬂ ammable and highly explosive under certain conditions. Be sure the ignition key is off and do not smoke or allow open ﬂ ame in the area while servicing. Wipe up any spilled fuel immediately.

WARNING

Extreme caution must be exercised when servicing the fuel system. The fuel system operates under high pressure. Use caution when removing or replacing components, as residual pressure may be present.

WARNING

Make sure that there are no fuel leaks before closing the engine hatch.

WARNING

Visually inspect unit for fuel leaks before operating the engine. If fuel leaks are present, DO NOT operate the engine, contact your service center immediately.

air ingestion caused by fuel tank slosh, and provides the necessary ﬁ ltration and water separation.

The FCC incorporates two (2) fuel pumps to provide an uninterrupted ﬂ ow of fuel to your PCM marine engine. Fuel is fed into the FCC bowl by a low-pressure, highvolume electric fuel pump. This pump ﬂ ows fuel at a volume much greater than the fuel ﬂ ow rate required of the high-pressure pump and engine demands. The highpressure pump, mounted inside the FCC bowl, provides the necessary fuel pressure and volume to maintain proper engine performance. The FCC constantly has an ample supply of fuel to meet the idle, cruise and acceleration fuel requirements of the engine.

The fuel pressure regulator, located on the fuel rail, controls the fuel pressure, and maintains a constant pressure across the fuel delivery system. Excess fuel, not used by the engine, returns to the FCC bowl.

The fuel delivered to the engine by the FCC is ﬁ ltered by a ﬁ lter and water separator element, which surrounds the high pressure pump inside the FCC bowl.

As indicated above, fuel enters the FCC bowl from two (2) locations, the low-pressure pump (initial input) and the fuel return line from the fuel pressure regulator (unused, recirculating fuel). Fuel exits the FCC bowl at two (2) locations, the high-pressure output to the fuel injection system and all excess fuel in the FCC bowl is routed back to the tank via the return line.

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FUEL

SUPPLY

LINE

ENGINE MAINTENANCE - 11

FUEL

RETURN

LINE

FUEL

CONTROL

CELL

LOW-PRESSURE

FUEL PUMP

Figure 11-12 Fuel Control Cell (FCC) Fuel System (Typical)

Servicing the FCC

The frequency of draining the water or replacing the ﬁ lter element is determined by the contamination level of the fuel. Replace the ﬁ lter element at least once a year, or when a loss of power is noticed (whichever occurs ﬁ rst).

WARNING

Improper use, installation or servicing may cause an explosion or ﬁ re resulting in bodily injury, or death. This unit should only be serviced by a qualiﬁ ed technician. Read and follow all instructions before proceeding. Run the engine and check for fuel leaks after installation, element replacement or draining the bowl. DO NOT remove the FCC bowl unless servicing the ﬁ lter element, otherwise contamination or bowl O-ring swelling may result.

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ENGINE MAINTENANCE - 11

Primary Fuel Filter

WARNING

Extreme caution must be exercised when servicing the fuel system. The fuel system operates under high pressure. Use caution when removing or replacing components, as residual pressure may be present.

Draining the FCC Bowl, ENGINE OFF

1. Disconnect the two-wire electrical connector.

2. Hold the 3/4” jam nut, located at the bottom of the FCC bowl, with a wrench. Remove the 7/16” plug, and drain the bowl contents into an approved container.

CAUTION: Both fuel and water will drain from the FCC bowl.

3. Apply pipe sealant, suitable for use with gasoline, to the threads of the 7/16” plug.

4. Tighten the 7/16” plug while holding the 3/4” jam nut with a wrench.

5. Reconnect the two-wire electrical connector.

6. Cycle the ignition key several times to run the electric fuel pumps and ﬁ ll the FCC bowl with fuel. Inspect the drain plug area for leaks. Correct any leaks prior to operating the engine.

7. Start the engine and inspect for fuel leaks. Correct any leaks prior to operating the engine any further.

FUEL

PUMP

"O"- RING

FUEL

FILTER

FUEL

BOWL

Filter Element Replacement, ENGINE OFF

1. Disconnect the two-wire electrical connector.

2. Hold the 3/4” jam nut, located at the bottom of the FCC bowl, with a wrench. Remove the 7/16” plug, and drain the bowl contents into an approved container.

CAUTION: Both fuel and water will drain from the FCC bowl.

3. Using a strap-type oil ﬁ lter wrench, remove the FCC bowl by turning it counterclockwise as view from the bottom.

4. Slide the bowl downward over the suspended ﬁ lter element. It may be necessary to pull the unit to one side in order to remove the FCC bowl.

5. Remove the fuel ﬁ lter element from the suspended pump by gripping the fuel pump with one hand, and pulling the ﬁ lter element downward with the other hand.

6. Push on new ﬁ lter element (part number RP080026) over the electric fuel pump.

FUEL

DRAIN

Figure 11-13 Fuel Control Cell (FCC)

7. Using a pick made of soft material, such as a toothpick, remove the old O-ring from the inside of the FCC bowl mounting head.

CAUTION: The mounting head O-ring groove may be damaged by using sharp steel tools to remove this O-ring.

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8. Lubricate the new O-ring with a light grease and install the new O-ring into the FCC bowl mounting head.

9. Apply pipe sealant, suitable for use with gasoline, to the threads of the 7/16” plug.

10. Install and tighten the 7/16” plug while holding the 3/4” jam nut with a wrench.

11. Grease taper and the threads on the FCC bowl and, by hand, thread the FCC bowl into the FCC mounting head. Tighten the bowl ﬁ rmly back into the mounting head with an oil ﬁ lter wrench.

12. Reconnect the two-wire electrical connector.

13. Cycle the ignition key several times to run the electric fuel pumps and ﬁ ll the FCC bowl with fuel. Inspect the drain plug area for leaks. Correct any leaks prior to operating the engine.

14. Start the engine and inspect for fuel leaks. Correct any leaks prior to operating the engine any further.

DO NOT ATTEMPT TO SERVICE ANY OTHER PARTS ON THIS UNIT.

ENGINE MAINTENANCE - 11

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ENGINE MAINTENANCE - 11

WARNING

Make sure there are no fuel leaks before closing the engine hatch.

Priming Fuel System

To prime the fuel system, cycle the ignition key 3 times using the following procedures:

1. Turn ignition key to ON position for 5 seconds.

2. Turn ignition key OFF.

FLAME

ARRESTOR

FLAME

ARRESTOR

FASTENERS

3. Pause for 10 seconds.

4. Repeat steps 1-3 three times. Crank the engine until it starts or 30 seconds elapse. If

the engine does not start, repeat the priming procedures.

FLAME ARRESTOR

At speciﬁ ed intervals, the ﬂ ame arrestor should be checked for blockage caused by dirt or other foreign material.

Loosen the clamp securing the ﬂ ame arrestor to the air intake tube or throttle body. Remove the ﬂ ame arrestor. Clean the ﬂ ame arrestor with solvent and dry with compressed air. Reinstall the ﬂ ame arrestor and tighten the clamp(s) securely.

THROTTLE

BODY

Figure 11-14 Flame Arrestor - 5.7L (Typical)

CLAMP

(NOT SHOWN)

FLAME

ARRESTOR

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THROTTLE

BODY

Figure 11-15 Flame Arrestor - 8.1L (Typical)

DRIVE BELT INSPECTION

Inspect the drive belt for excessive wear, shredding or missing sections.

Inspect the drive belt for contamination from excessive dirt, oil, coolant or other substances that may effect the drive belt operation.

If a problem is found, replace the belt after inspecting the following items:

ENGINE MAINTENANCE - 11

CAUTION

The replacement of the drive belt requires the removal of the inlet hose from the sea-water pump. With the hose removed, it is possible for water to enter the bilge of the boat, and possibly sink it. ALWAYS plug the inlet hose securely to prevent this possibility from occurring.

DRIVE BELT REPLACEMENT (8.1L)

• All pulleys and tensioners for signs of misalignment

• All pulleys and tensioners for signs of rust or other damage

• Bent pulleys or tight bearings in the engine water circulation pump, sea-water pump and alternator

8.1L ACCESSORY DRIVE BELT

The PCM 8.1L engine uses a single serpentine belt to drive the engine water circulation pump and the alternator. The sea-water pump is mounted onto the crankshaft pulley and is driven directly by the crankshaft.

1. Remove the inlet and outlet hoses from the sea water pump, being careful not to allow the hose clamps to fall into the bilge.

2. Remove the bolt and washers that attach the sea-water pump to the bracket, being careful not to allow the bolt and washers to fall into the bilge.

3. Loosen the bolts that attach the bracket to the engine block until a gap, large enough to pass the belt through, is created.

4. Note the routing of the belt before removing.

ALTERNATOR

PULLEY

CIRCULATION

BELT

TENSIONER

PUMP AND

ALTERNATOR

DRIVE BELT

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CIRCULATION

PUMP PULLEY

CRANKSHAFT

PULLEY

IDLER

PULLEY

(if equipped)

Figure 11-16 8.1L Accessory Drive Belt Conﬁ guration

ENGINE MAINTENANCE - 11

Figure 11-17 Belt Tensioner (8.1L)

5. Using a 15 mm box wrench or socket, turn the belt tensioner to relieve the tension on the belt. Slide the belt off of the pulleys and through the gap between the sea-water pump and the bracket. Release the tensioner slowly

to prevent the tensioner from snapping against its stop, and possibly causing damage to the tensioner.

7. Compress the belt tensioner, and slide the belt over the tensioner pulley. Release the tension slowly to tension the belt.

8. Position the bracket onto the sea-water pump anchor boss, and install the ﬂ at washer, lock washer and bolt to the pump.

9. Tighten the bracket-to-engine block attaching bolts to 18 lb. ft.

10. Tighten the bolt that secures the sea-water pump to the bracket to 12 lb. ft.

11. Install the inlet and outlet hoses to the sea-water pump. Position the hoses and clamps so that the clamps are clamping on the pump side of the ﬁ tting bead. Tighten the clamps securely.

6. Slide the new belt through the gap between the sea-water pump and the bracket. Slide the belt onto the pulleys using the same routing as noted prior to removal.

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6.0L ACCESSORY DRIVE BELT

The PCM 6.0L engine uses a single serpentine belt to drive the engine water circulation pump, sea-water pump and the alternator.

DRIVE BELT REPLACEMENT (6.0L)

1. Note the routing of the belt before removing.

2. Using a 15 mm box wrench or socket, turn the belt tensioner to relieve the tension on the belt. Slide the belt off of the pulleys. Release

the tensioner slowly to prevent the tensioner from snapping against its stop, and possibly causing damage to the tensioner.

ENGINE MAINTENANCE - 11

Figure 11-19 Belt Tensioner (6.0L)

Alternator

Belt

Tensioner

Idler

Circulation

Pump

Crankshaft

Pulley

Raw Water

Pump

Figure 11-18 6.0L Accessory Drive Belt Conﬁ guration

3. Slide the new belt onto the pulleys using the same routing as noted prior to removal.

4. Compress the belt tensioner, and slide the belt over the tensioner pulley. Release the tension slowly to tension the belt.

SERVICING RAW WATER PUMP IMPELLER (6.0L)

The raw water pump impeller should be serviced every 50 hours, or once a year, whichever occurs ﬁ rst. See Maintenance Schedule.

Locations “A” (Figure 11-18) are access holes in order to loosen the raw water pump attaching bolts. The bolts are secured in the pump by O-rings, and will not fall out during removal.

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ENGINE MAINTENANCE - 11

WARNING

Engine must be shut OFF and the ignition key removed before inspecting the drive belt(s). The drive belt(s) should be checked periodically for condition and tension. If the belt(s) shows signs of cracking, glazing or deterioration, replace with new belt(s).

ACCESSORY DRIVE “V”- BELT(S) (5.0/5.7L ENGINE)

Check the drive belt tension by pressing down on the belt midway between the two pulleys. The belt should depress 1/2 in. (13 mm). If depression is more than allowable, adjust the tension by loosening the adjustment bolt and the pivot bolt. Apply required pressure with a pry bar, or 1/2 in breaker bar, to tighten the belt tension. While maintaining pressure, tighten the adjusting bolt securely. Tighten the pivot bolt.

ADJUSTMENT

BOLT

RAW WATER

PUMP

RAW WATER

PUMP BELT

1/2"

DEFLECTION

ADJUSTMENT

BOLT

1/2"

DEFLECTION

ADJUSTMENT

BOLT

Figure 11-18 Drive Belt Location and Adjustment (5.0L / 5.7L)

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RAW WATER

PUMP

ALTERNATOR

BELT

CHANGING OILS

WARNING

IMPORTANT: The Federal Water Pollution Control Act prohibits the discharge of oil or oily waste into or upon the navigable waters and continuous zone of the United States, if such discharge causes a ﬁ lm or sheen upon, or discoloration of the surface of the water, or causes sludge or emulsion beneath the surface of the water. Violators are subject to a penalty of $5,000.00.

Refer to the MAINTENANCE SCHEDULE for oil change intervals. The engine and transmission oils should be changed prior to placing the boat into storage.

ENGINE MAINTENANCE - 11

OIL PUMP

DIPSTICK

CONTAINER

The transmission oil change should be performed by an authorized dealer, at speciﬁ ed intervals.

IMPORTANT: Change the engine oil when the engine is warm from operation. Warm oil ﬂ ows more freely, and allows more foreign material and impurities to be removed.

The engine oil ﬁ lter is remote mounted. The engine block location, where the ﬁ lter is normally mounted, is covered with an oil ﬁ lter bypass adapter. DO NOT remove this adapter when changing the oil.

1. With the engine at normal operating temperature, remove the dipstick and install a crankcase oil pump onto the dipstick tube (Figure 11-19). Insert the discharge hose into a suitable container. Pump the oil from the engine until the crankcase is empty. Remove the oil pump from the dipstick tube.

2. Remove the oil ﬁ lter by turning it counterclockwise, using an oil ﬁ lter wrench if necessary. Discard the old ﬁ lter and sealing ring.

Figure 11-19 Engine Oil Removal

3. Coat the sealing ring, on the new ﬁ lter, with a light coating of clean engine oil. Install the oil ﬁ lter securely by hand. DO NOT overtighten.

4. Fill the engine with the recommended oil, see OIL REQUIREMENTS, through the oil ﬁ ll location on the valve cover (Figure 11-20).

OIL FILL

CAP

5. Start the engine and operate for 5 minutes to circulate the oil throughout the engine. Check entire system for leaks, especially around the oil ﬁ lter.

6. Stop the engine and wait 5 minutes to allow the oil to completely drain down. Check the oil level and add oil, if needed, to bring the engine oil to the proper level.

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Figure 11-20 Engine Oil Fill (8.1L)

ENGINE MAINTENANCE - 11

ENGINE ALIGNMENT

CAUTION

Engine must be properly aligned, or vibration, noise and damage to the transmission output shaft oil seal and bearings may result.

IMPORTANT: Engine alignment MUST BE RECHECKED with the boat in the water, fuel tanks full and with a normal load on the boat. Engine must be aligned so that the transmission and the 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 surfaces on the transmission and the propeller shaft couplings. Make sure they are clean and ﬂ at.

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

• Push down and then lift the propeller shaft as far as it will move, then place the shaft in the middle of the movement.

• 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.

• 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.

Figure 11-21 Shaft Mating Surface Check

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Figure 11-22 Centering Propeller Shaft

ENGINE MAINTENANCE - 11

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 11-23 Angular Alignment

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ENGINE MAINTENANCE - 11

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:

• UP or DOWN ADJUSTMENT: Loosen the locking nut. Turn the adjusting nut or the adjusting bolt in the direction required to raise or lower the engine. After the adjustment is complete, tighten the locking nut.

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

LOCKING

NUT

ADJUSTING

NUT

1.0 (2

TRUNNION

BOLT

Figure 11-26 Engine Extension

• 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.

Figure 11-24 Mount Adjustment

LOCKING

NUT

Figure 11-25 Mount Adjustment

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.

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.

FASTENER TORQUE SPECIFICATIONS

Location Lb-Ft (N.m)

Engine Mount to Stringer Securely Propeller 50 (68) Trunnion Bolts 45 (61)

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ENGINE MAINTENANCE - 11

ENGINE MAINTENANCE LOG

Operating Date Maintenance/Repair Hours

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ENGINE MAINTENANCE - 11

MAINTENANCE SCHEDULE

After 1st Every 50 Every 100 Location and Service Check 25 Hrs of Hours of Hours of Once Daily Operation Operation Operation Each Year

Check coolant level - Fresh-water cooled

models only X Check oil level - Engine crankcase X Check oil level - Transmission X Engine Assembly (complete - Check for

obvious leaks (water, oil, fuel and exhaust) X Remote Control and Steering System -

Check for proper operation X Sea Strainer - Check (if equipped) X Cooling System - Check condition and

tightness of all hose clamps X X Cooling System - Replace raw water

pump impeller X X Drive Belt - Inspect condition and check

tension X X X Exhaust System - Check condition and

tightness of all hose clamps X X Exhaust System - Check for water leaks at

the manifold, riser and elbow gaskets X Ignition System and Spark Plugs - Clean

and inspect condition O O O Engine Assembly (complete) - Check for

loose, missing or damaged parts (especially engine mounts, starter and alternator mounting fasteners) X X X

Change engine oil and ﬁ lter X X X Engine Alignment - Check and adjust if

necessary O O

Ignition Timing - Not Adjustable Battery - Check electrolyte level and

speciﬁ c gravity. Inspect case for damage. Check cables and connections. X X X

Electrical System (complete) - Check for loose or dirty connections and damaged wiring X

Flame Arrestor and Crankcase Ventilation System - Clean and inspect X X

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ENGINE MAINTENANCE - 11

MAINTENANCE SCHEDULE (cont’d)

After 1st Every 50 Every 100 Location and Service Check 25 Hrs of Hours of Hours of Once Daily Operation Operation Operation Each Year

Hoses (all) - Inspect for cracks, swelling,

weather checking or other signs of deterioration X X

Shift and Throttle Cable Linkage - Inspect and lubricate (A) X1 X

Fuel Filters - Service or replace O O Transmission and “V” Drive - Change

ﬂ uid (B,C) and clean strainer, if equipped O O

MAINTENANCE SCHEDULE (cont’d)

Fresh-water cooled models - Clean sea-water section As required 3 (X) Fresh-water cooled models - Check coolant for alkalinity At least once each year (X) Fresh-water cooled models - Change coolant Every ﬁ ve years Zinc Anodes - Heat exchanger and cooler - check condition Every 30 days 3 (X) Engine Assembly Exterior Surfaces - spray with rust- Fresh water areas - Every 60 days (X)

preventative oil (D) Salt water areas - Every 30 days (X) Cooling System (SALT WATER AREAS ONLY) - Flush

sea-water section After use each day (X)

Notes:

In fresh-water areas, every 100 hours of operation or

120 days (whichever occurs ﬁ rst). In salt-water areas, (X) Denotes service to be performed by the owner/ operator

(O) Denotes service to be performed by an authorized PCM Engines dealer

every 50 hours of operation or 60 days (whichever

occurs ﬁ rst).

In fresh-water areas, every 50 hours of operation or 60 days (whichever occurs ﬁ rst). In salt-water areas, every 25 hours of operation or 30 days (whichever occurs ﬁ rst).

(A) Use SAE 30 engine oil

Requires more frequent inspection if used in extremely

(B) All Velvet Drive and Hurth transmissions - Use

salty, polluted or mineral-laden waters.

Dexron III automatic transmission ﬂ uid

See COOLANT SPECIFICATIONS.

All Walters “V” Drive transmissions - Use Exxon Spartan EP-68 or SAE 30 engine oil

(D) Use WD-40 penetration oil or equivalent

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ENGINE MAINTENANCE - 11

VISUAL INSPECTION

Touch up scratches, nicks and corrosion damage to the exterior ﬁ nish of the engine. Spray paint may be obtained

It is important for the owner/operator to visually inspect

from your local PCM Engines dealer. the complete engine assembly at regular intervals. Most often, costly repairs can be avoided if potential problems are corrected before there is a failure.

Protect engine ﬁ nish from corrosion by periodically

spraying the engine exterior ﬁ nish with a rust

preventative oil (such as WD-40). Inspect the complete engine assembly for obvious fuel, oil, water or exhaust leaks. Check for loose, damaged or missing parts. Check all hose clamps for adequate tightness. Check the electrical system for loose or dirty connections or damaged wiring.

ENGINE FLUID CAPACITIES

Model MP 5.0L / 5.7L MP 6.0L MP 8.1L Crankcase Oil Capacity

W / New Filter 4 Quarts (3.8 L) Fresh Water Cooling

System Capacity 23 Quarts (21.85 L) 18 Quarts (17.01 L) 33 Quarts (31.35 L)

5 Quarts (4.75 L)1

7 Quarts (6.65 L)

TRANSMISSION FLUID CAPACITIES

Model All Models Type PCM, 1:1 Ratio PCM, 1.23:1 Ratio Hurth (Exc. V-Drive), All Ratios Hurth V-Drive, All Ratios Walters RV-36D V-Drive 1.5 Quarts (1.42 L) SAE 30 1 - Capacities are dependent on installation angle. Oil capacities are approximate, and may not include capacity

needed for transmission cooler and oil lines. Always use the dipstick to determine the exact quantity of oil required. 2 - Check the transmission ﬂ uid level at operating temperature and immediately after shutdown of the engine.

1,2

2.0 Quarts (1.9 L) DEXRON III

1,2

2.0 Quarts (1.9 L) DEXRON III

1,2

4.0 Quarts (3.79 L) DEXRON III

1,2

4.5 - 5.0 Quarts (4.26 - 4.73 L) DEXRON III

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ENGINE MAINTENANCE - 11

FILTER REQUIREMENTS

Description Part No. Oil Filter (remote-mounted) R077001 Fuel Control Cell (FCC) Fuel Filter Element RP080026

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ENGINE SPECIFICATIONS - 12

4.25 in. (107.95 mm) 4.25 in. (107.95 mm)

4.370 in. (111.0 mm) 4.370 in. (111.0 mm)

) (385 HP) (425 HP)

370 HP

4.0007 in. (101.618 mm)

9.1:1 9.1:1

9.4:1

3.622 in. (92.0 mm)

ENGINE SPECIFICATIONS

FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C)

3600 3800

4100

5000-5200 4200 - 4600 4400 - 5000

FWC 160˚F (76.7˚C)

(896 - 1103 kPa) (896 - 1103 kPa) (896 - 1103 kPa) (896 - 1103 kPa) (896 - 1103 kPa)

Compression Pressure 130 - 160 psi 130 - 160 psi 130 - 160 psi 130 - 160 psi 130 - 160 psi

Compression Ratio 9.4:1 9.4:1

Stroke 3.48 in. (88.3 mm) 3.48 in. (88.3 mm)

Bore 3.75 in. (95.0 mm) 4.0 in. (101.6 mm)

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

(Horsepower) (275 HP) (330 HP) (

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

(379-427 kPa) (379-427 kPa) (379-427 kPa) (234-325 kPa) (234-325 kPa)

Fuel Pressure 55-62 psi 55-62 psi 55-62 psi 34-47 psi 34-47 psi

at Idle at Idle at Idle at Idle at Idle

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

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

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

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

Cruising RPM (Max) 3600 3800

WOT Operating RPM 4400 - 5000 4800 - 5000

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Alternator Rating 70 Amps 70 Amps 70 Amps 70 Amps 70 Amps

Ground Ground Ground Ground Ground

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

FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C)

Thermostat RWC 160˚F (61.7˚C) RWC 160˚F (61.7˚C) RWC 160˚F (61.7˚C) RWC 160˚F (61.7˚C)

120 Ah 120 Ah 120 Ah 120 Ah 120 Ah

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

ENGINE SPECIFICATIONS - 12

5.0 / 5.7 Liter

LH ROTATION

FRONT

Rotation

6.0 / 8.1 Liter

LH ROTATION

FRONT

DISTRIBUTOR

FLYWHEEL END OF ENGINE

ALL V-8 MODELS

FIRING ORDER:

1-8-4-3-6-5-7-2

Figure 12-1 V-8 Firing Orders

TUNE-UP SPECIFICATIONS

MP 5.7L (330 HP) MP 6.0L (370 HP) MP 8.1L (HO) (425 HP)

Spark Plug Type AC - MR43LTS

(1.52 mm) (1.52 mm) (1.52 mm)

Not Adjustable Not Adjustable Not Adjustable

MP 5.0L (275 HP) MP 8.1L(STD) (385 HP)

Model

Spark Plug Gap

Ignition Timing

0.060 in. 0.060 in. 0.060 in.

Fixed, Fixed, Fixed,

FIRING ORDER:

1-8-7-2-6-5-4-3

NGK - PZTR5A-15 Denso - TJ14R-P15

Firing Order

(LH Rotation) (LH Rotation) (LH Rotation)

1-8-4-3-6-5-7-2 1-8-7-2-6-5-4-3 1-8-7-2-6-5-4-3

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OUT-OF-SEASON STORAGE - 13

ENGINE STORAGE

IMPORTANT: This service should be performed by an

Authorized PCM Dealer.

CAUTION

Refer to FLUSHING COOLING SYSTEM before proceeding.

1. Fill the fuel tanks with gasoline (that does not contain alcohol) and add a sufﬁ cient amount of gasoline stabilizer, such as STA-BIL™ fuel stabilizer, to prevent the formation of fuel gum and varnish. Follow the instructions on the container.

IMPORTANT: If the boat is to be place into storage with fuel containing alcohol in the fuel tanks, the engine fuel system must be run dry at idle RPM. Fuel tanks should be drained completely and fuel conditioner, such as STA-BIL™, added to any fuel remaining in the tanks.

2. Run the engine and allow it to reach normal operating temperature. Shut down the engine and change the oil and oil ﬁ lter (See ENGINE MAINTENANCE).

4. Remove the ﬂ ame arrestor and start the engine.

Operate the engine at a fast idle speed

(1000-1500 RPM). Use an aerosol-type fogging

solution and spray sufﬁ cient amount, into the

throttle body assembly bores, to treat internal

surfaces of the engine. Refer to the instructions

on the fogging solution canister. Turn the ignition

switch to the OFF position.

5. Clean the ﬂ ame arrestor and the vent hoses,

and reinstall on the engine. Cover the throttle

body assembly, to prevent the possibility of the

water entering the engine through the throttle

body assembly, during storage.

6. Close the fuel shut-off valve (if equipped).

3. Flush the cooling system if operating in salt water or brackish water areas. (See ENGINE MAINTENANCE).

NOTICE: If the engine is equipped with the optional fresh-water cooling system, refer to draining and reﬁ lling procedures. The fresh-water cooling system must be serviced before fogging the engine for storage.

WARNING

Operate the bilge blower and be sure no fuel vapors are present when treating the engine. Be sure the engine compartment is well-ventilated to prevent a potential ﬁ re hazard.

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DRAINING INSTRUCTIONS

CAUTION

OUT-OF-SEASON STORAGE - 13

If the boat is to remain in the water during or after draining, close the seacock to prevent a siphoning action that may occur, allowing sea water to ﬂ ow from drain holes or removed hoses.

IMPORTANT: When removing the drain plugs, insert a wire into the hole to remove any obstruction which would prevent water from draining completely.

RAW-WATER COOLED MODELS

1. Remove all the drain plugs from the following locations:

• Cylinder Block - one on each side (5.0/5.7L engines, remove the knock sensor on the port side). When installing the knock sensor, torque to 20 N.m (15 lb ft).

• Exhaust Manifolds - remove hoses and/or drain plugs, one on each side

• Transmission and Engine Cooler - one drain plug

LARGE

HOSE

DRAIN

LOCATION

Figure 13-1 Draining Engine Circulating Pump (5.0/5.7L)

2. Remove the hose from the inlet side of the sea water pump.

3. Remove the large hose from the engine circulating pump, or drain plug (if equipped).

NOTICE: It may be necessary to bend or lift the hoses to allow water to drain completely.

4. Crank the engine over once to purge any trapped water in the sea-water pump. DO NOT allow the engine to start.

5. After the water has completely drained, coat the threads of the drain plugs with PerfectSeal (or equivalent), and reinstall in the proper locations. Reinstall all the hoses and tighten the clamps securely.

Remove large HOSE, or DRAIN PLUG (if equipped)

Figure 13-2 Draining Engine Circulating Pump (5.0/5.7L)

NOTICE: For additional protection against freezing and corrosion, you may wish to ﬁ ll the engine with antifreeze. If ethylene glycol based antifreeze is used, check with local environmental agencies about the proper disposal of antifreeze. It may be necessary to drain the system prior to re-commissioning the boat.

6. Remove the hoses which connect to the exhaust manifolds from the thermostat housing.

7. Remove the large circulating pump hose from the thermostat housing. Pour the mixture of antifreeze and water, properly mixed to protect the engine to the lowest temperatures that it will be exposed to, into the circulating pump hose and ﬁ ll the engine block. Pour additional antifreeze solution into the hoses connected to the exhaust manifolds.

8. Reinstall the hoses into the thermostat housing and tighten the hose clamps securely.

After draining is completed, perform the additional required maintenance as outlined in the MAINTENANCE SCHEDULE under ONCE EACH YEAR.

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OUT-OF-SEASON STORAGE - 13

FRESH-WATER COOLED MODELS

IMPORTANT: The fresh-water section of the cooling

system must be kept ﬁ lled year around with recommended coolant. Make certain that the cooling system is protected with an ethylene glycol antifreeze mixture properly mixed to protect the engine to the lowest temperature that it will be exposed to.

See DRAINING FRESH-WATER COOLING SYSTEM in ENGINE MAINTENANCE section for draining and reﬁ lling procedures of FWC system, if required.

IMPORTANT: Drain sea-water section of the cooling system only. See Water Flow Diagrams in the back of this manual to illustrate the drain locations.

1. Remove all the drain plugs from the following locations:

• Heat Exchanger - one on outboard side

• Exhaust Manifolds - remove hoses and/or drain plugs, one on each side

4. After the water has completely drained, coat the

threads of drain plugs with PerfectSeal, or

(equivalent), and reinstall in the proper locations.

Reinstall the hoses and tighten all the clamps

securely.

After draining is completed, perform the additional

required maintenance as outlined in the MAINTENANCE

SCHEDULE under ONCE EACH YEAR.

BATTERY STORAGE

Follow the battery manufacturer’s instructions for

storage. If not available, use the following instructions:

• Remove the battery from the boat and clean,

removing dirt and grease from the top of the

battery.

• Fill the battery with distilled water to the

manufacturer’s speciﬁ cations.

• Store the battery in a cool, dry place. Do not

store on a concrete surface.

• Engine Cooler - one drain plug

2. Remove the hose from the inlet side of the sea water pump.

3. 6.0L ONLY - Remove the hose from the outlet side of the sea-water pump.

4. Crank the engine over once to purge any trapped water in the sea-water pump. DO NOT allow the engine to start.

• Periodically (every 30 to 45 days), check

the water level and recharge the battery to the

manufacturer’s speciﬁ cations. Do not fast

charge.

CAUTION

A discharged battery can be damaged by freezing.

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OUT-OF-SEASON STORAGE - 13

FITTING OUT AFTER STORAGE

When recommissioning the engine after storage, the following items should be checked:

• Check all the cooling system hoses. Be sure they are properly connected and all the hose clamps are tight.

CAUTION

When installing the battery, make certain that you connect the POSITIVE (+) BATTERY CABLE to the POSITIVE (+) BATTERY TERMINAL ﬁ rst, and the NEGATIVE (-) BATTERY CABLE to the NEGATIVE (-) BATTERY TERMINAL last. If the battery cables are reversed, the electrical system will be damaged.

WARNING

Do not use jumper cables and/or a booster battery to start the engine. Do not recharge a weak battery in the boat. Remove the battery and recharge in a ventilated area away from fuel vapors, sparks or open ﬂ ame.

• Install the fully charged battery. Be sure that all the connections are clean and free from corrosion. Coat the battery terminal connections with an anti-corrosion battery terminal spray.

• Refer to the OPERATING INSTRUCTIONS section and perform all the safety checks before starting the engine.

CAUTION

If the engine(s) is to be started prior to launching, use the procedure FLUSHING COOLING SYSTEM before proceeding to start the engine(s).

• Open the seacock before starting the engine.

• Start the engine and closely observe the instrument panel. Allow the engine to reach normal operating temperature. Inspect the engine carefully for fuel, exhaust, oil and water leaks.

• Check the steering, shift and throttle controls for proper operation.

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TROUBLESHOOTING - 14

Engine performance complaints usually fall under one of the basic headings listed in the Troubleshooting Guide. When a problem cannot be easily diagnosed, consult a PCM Engines Servicing Dealer for assistance.

Malfunction Possible Cause Corrective Action

Engine will not crank with the Problem with the engine Contact PCM Engines starter motor, or cranks slowly. management system. Dealer.

Battery switch turned OFF (if Turn the battery switch ON. equipped)

Remote control not in Neutral Position the remote control exactly NOTICE: Battery voltage position. in Neutral. must be AT or ABOVE 10 volts while the engine is cranking Blown the ignition fuse or open Replace the fuse - reset circuit or the engine management system circuit breakers. breakers. will not function. Loose and/or dirty wiring Check the battery cables and connections. starter circuit wiring. Clean and tighten all connections. Repair or replace the damaged wiring.

Dead Battery Recharge, test and replace as necessary.

Engine Cranks - will not Improper starting procedure. Refer to “STARTING start or is hard starting. ENGINE” in the OPERATING INSTRUCTIONS section.

NOTICE: Battery voltage No fuel - empty fuel tank Check the fuel tank level - ﬁ ll must be AT or ABOVE 10 tank(s). Open shut-off valve(s). volts while the engine is cranking or the engine management system Plugged fuel ﬁ lters. will not function. No fuel to the throttle body (TBI) Plugged or kinked fuel lines or or the injectors (MPI) plugged fuel-tank vent. Faulty fuel pump - check electrical connections. Faulty anti-siphon valve.

Engine ﬂ ooded Open the throttle 100% and crank the engine. When the engine starts, immediately return the throttle to 1000 RPM.

Ignition system malfunction Contact PCM Engines Dealer. Contaminated fuel Check fuel for water or other

contamination. If contaminated, drain and clean the fuel system.

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TROUBLESHOOTING - 14

Malfunction Possible Cause Corrective Action

Engine Overheats Loose or worn drive belt(s) Adjust or replace the belts as necessary.

Collapsed, kinked or leaking Replace the hoses. hoses.

Transmission/engine oil cooler Remove the water hoses and ﬂ ush plugged in opposite direction of the normal ﬂ ow.

Faulty thermostat Replace the thermostat. Sea-water intake valve Open the valve completely.

partially/fully closed. Restricted sea-water pickup Remove restriction. Faulty temperature sending unit Test and replace as necessary.

or gauge Sea-water pump impeller worn or Replace the impeller.

damaged The following applies to engines Coolant level low in the fresh-water Check the cooling system for leaks.

equipped with Fresh-Water section of the cooling system Reﬁ ll the system. See Warning Cooling (FWC) systems. before removing the ﬁ ll cap.

Heat exchanger passages plugged Clean and ﬂ ush the exchanger. with scales and debris

Improper coolant mixture Install the proper coolant mixture (50% antifreeze - 50% water).

Insufﬁ cient engine temperature Faulty thermostat Replace the thermostat. Faulty temperature sender Replace the temperature sender. Engine oil pressure low Faulty oil pressure sending unit Test and replace as necessary.

or gauge Oil level low Add speciﬁ ed oil. Check the engine

for leaks. Crankcase overﬁ lled causing oil Remove the required amount of oil.

aeration Determine the cause of overﬁ lled condition (improper ﬁ lling, etc.).

Diluted or improper grade/ Change the oil and ﬁ lter. viscosity of oil Determine the cause of dilution. (insufﬁ cient engine temperature, excessive idling, etc.)

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TROUBLESHOOTING - 14

Malfunction Possible Cause Corrective Action

Transmission slipping - Low oil level Add speciﬁ ed oil. Check the erratic operation transmission for leaks.

Transmission overﬁ lled causing Drain required amount of oil. oil aeration

Transmission shift lever not fully Adjust the shift linkage and remote engaged control. Check the shift cables for freedom of movement and binding.

Contaminated ﬂ uid Determine and correct the contamination source and change the ﬂ uid.

Engine misses, runs rough Ignition system malfunction Contact PCM Engines Dealer. and/or backﬁ res

Plugged fuel ﬁ lters Replace the fuel ﬁ lters. Faulty fuel pump. Have fuel pump replaced by a

PCM Engines Dealer/ Plugged or kinked fuel lines or Repair or replace the fuel lines.

fuel tank vent Remove obstruction. Anti-siphon valve faulty Clean or replace as necessary. Flame arrestor dirty Clean the ﬂ ame arrestor. Poor engine or boat Ignition malfunction Contact PCM Engines Dealer.

performance Throttle not fully open Check the remote control and throttle body linkage for freedom of movement and proper adjustment.

Damaged or improper propeller Repair or replace as necessary. Excessive water in the bilge Pump the water out and investigate

source of entry. Excessive growth on the boat Clean the bottom and paint with an

bottom anti-fouling paint. Boat overloaded Reduce and/or redistribute the load. Dirty ﬂ ame arrestor Clean the ﬂ ame arrestor. Engine overheating Repair the cooling system (See

“Engine Overheats”).

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TROUBLESHOOTING - 14

This Page Was

Intentionally

Left Blank

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WATER FLOW DIAGRAMS - 15

m (15 lb ft)

Knock Sensor

Torque 20 N

Figure 15-1 Raw-Water Cooling System (5.0/5.7L Belt-Driven Raw Water Pump)

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= RAW WATER FLOW

= Drain Locations

WATER FLOW DIAGRAMS - 15

Manifold

From Intake

Block

To Cylinder

Block

To Cylinder

= RAW WATER FLOW

= FRESH WATER FLOW

= Drain Locations

Figure 15-2 Fresh-Water Cooling System (5.0/5.7L)

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WATER FLOW DIAGRAMS - 15

Remove Hose from

raw water pump and drain hose

completely

IMPORTANT: Accessory (i.e. heater, hot water tank) Hook Up

A tee may be inserted anywhere in the specified hose for most appropriate routing.

HOSE 1 - Water OUT to heater or hot water tank

HOSE 2 - Water RETURN from heater or hot water tank

NOTE: Location is the cooling system bypass. This bypass hose MUST NOT be

tampered with. DO NOT hook up any external accessories (i.e. heaters, hot water tanks) at this location.

Figure 15-3 Fresh-Water Cooling System (6.0L)

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= RAW WATER FLOW

= FRESH WATER FLOW

= 7 Drain Locations

WATER FLOW DIAGRAMS - 15

Figure 15-4 Raw-Water Cooling System (8.1L)

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= RAW WATER FLOW

= Drain Locations

WATER FLOW DIAGRAMS - 15

Block

To Engine

Block

To Engine

=RAWWATERFLOW

= FRESH WATER FLOW

= Drain Locations

Figure 15-5 Fresh-Water Cooling System (8.1L)

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INSTRUMENTATION WIRING DIAGRAMS - 16

WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS

NUMBER NAME WIRE COLOR

1. GROUND BLACK

2. TACHOMETER GRAY

3. WATER TEMPERATURE TAN

4. ENGINE ALARM TAN/BLACK

5. IGNITION PURPLE/WHITE

6. BATTERY RED/WHITE

7. STARTER YELLOW/RED

8. OIL PRESSURE LT. BLUE

9. CHECK ENGINE LIGHT BROWN/WHITE

10. DATA LINE ORANGE/BLACK

NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.

NOTE THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS.

: POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM

Figure 16-1 Typical Instrumentation Wiring

ENGINE

HARNESS

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LITERATURE - 17

To obtain service and/or parts literature for your PCM Marine Engine, contact the following:

PCM Engines

Pleasurecraft Engine Group

Publications Department

1737 Highway 76 East

Little Mountain, SC 29075

1. SERVICE: For more detailed information, PCM has a detailed service manual available. This manual contains complete engine and component disassembly and reassembly instructions. Troubleshooting and maintenance charts are also included.

2. PARTS: Parts manuals with exploded views for service parts are available for all current engine models.

IMPORTANT: When contacting the factory for service information, be sure to include your engine model and serial number to insure the service information you receive is correct.

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FORMS - 18

PCM WARRANTY TRANSFER APPLICATION

The remainder of the original PCM limited warranty is transferable within thirty (30) days of date of sale by the original owner/user to a subsequent purchaser for the remainder of the unused portion of the original warranty term, provided the engine does not have in excess of 300 hours. The original date of sale or original in-service date (whichever comes ﬁ rst) begins the warranty coverage period.

Direct Sale by Owner/Dealer Promo/Ski Show User/ or First Operator:

• The second purchaser can be registered as the owner and retain the unused portion of the warranty term by sending the following:

- Original owner’s plastic Warranty Registration Card

- Copy of Bill of Sale/Sales Contract/Operator Contract

- Completed Warranty Transfer Application

- Warranty transfer fee

Transfer Fee:

• The fee for transfer is $100.00. The applicable transfer fee must be submitted via certiﬁ ed check within 30 days of date of sale along with the transfer application information to: Pleasurecraft Engine Group P.O. Drawer 369 Little Mountain, S.C., 29075

• A Warranty Registration Card will be issued to the second owner, reﬂ ecting the change has been made in the factory computer.

OUTSIDE THE U.S. AND CANADA, CONTACT YOUR LOCAL PLEASURECRAFT DEALER OR WARRANTY SERVICES AT (803) 345-0050 FOR MORE INFORMATION ON HOW TO APPLY TO THIS PROGRAM.

IMPORTANT! PURCHASER NOTICE: The checks listed below are designed to insure safety and satisfaction. Therefore, we require the

following inspection be performed at your expense by a qualiﬁ ed technician prior to delivery. By signature the technician certiﬁ es that he/she has checked the installation and operation of the engine and ﬁ nds it to be performing properly. All terms in the Limited Warranty located in the

Engine Owners Manual still apply.

PRE-DELIVERY POINTS CHECKLIST

(TECHNICIAN TO CHECK ALL POINTS AND SIGN BELOW)

___ ENGINE OIL ___SHAFT ALIGNMENT ___TIMING ___DRIVE LUBE ___CONTROL ADJUSTMENTS ___EXHAUST HOSES/CLAMPS ___BATTERY CHARGE AND LEVEL ___CONTROL TRAVEL ___ALTERNATOR CHARGE ___TIGHTEN WATER LINES ___TIGHTEN DRAIN PLUGS ___SET IDLE SPEED ___CHECK LUBE POINTS ___BELT TENSION ___PROP SIZE & ROTATION ___

CHECK FOR LEAKS

ENGINE MODEL:_______________________________ ENGINE SERIAL:___________________________________________ TRANS. SERIAL:_______________________________ ENGINE HOURS:___________________________________________

DATE OF SALE (1st Owner/1st Operator) ______/______/______ DATE OF SALE (2ND Owner) ______/______/______ (New Owner)

NAME:__________________________________________________________________________________________________________________ ADDRESS:______________________________________________________________________________________________________________ CITY,STATE, ZIP___________________________________________________________________________________________ (Previous Owner)

I hereby certify the pre-delivery checklist on engine #___________

and have corrected any abnormality revealed by this inspection.

________________________________ ____________________________________ ____________________________

(Technician Signature, Dealer & Date) (Seller’s Signature & Date) (Purchaser’s Signature & Date)

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FORMS - 18

PCM

SUMMARY OF WARRANTY TERM LIMITS

This list does not, in any way, modify the ofﬁ cial Limited Warranty Statement of PCM. This list has been compiled only as a general outline of year and hour limits imposed on different models of PCM engines. Please review the ofﬁ cial Limited Warranty Statements on the following pages for speciﬁ c terms and limitations as they apply to the particular engine / component involved.

ENGINE MODEL YEAR: WARRANTY COVERAGE TERM:

1992 & OLDER 1 year, 200 hours. Engine and Transmission. 1993 2 years, 200 hours. Engine and Transmission 1994 - 1996 3 years, 200 hours, Ford engine. 2 years, 200 hours Transmission.

2 years, 200 hours, GM engine. 2 years, 200 hours. Transmission. 1997* - 1999 3 years, unlimited hours, Ford and GM. 2 years, unlimited hours Transmission. 2000 3 years, unlimited hours, Ford and GM. 3 years, unlimited hours Transmission. 2001** 3 years, unlimited hours, Ford and GM. 3 years, unlimited hours Transmission 2002 ** 3 years, unlimited hours, Ford and GM. 3 years, unlimited hours Transmission 2003 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission Base Engine 1 year, 200 hours with exclusions. Note:

* 1997 model year engine in a Correct Craft vessel offered 3 Year Warranty on GM engines * 1997 PCM and later model year engines offered transferable warranty. (Does not apply to any earlier model) ** Special 25th Anniversary Edition PCM Ford GT-40 engines, have a fourth year of product protection on all internal engine components supplied by Ford Power Products.

PCM OWNERSHIP CHANGE NOTICE

If you are the new owner of a Pleasurecraft Marine Engine on which the warranty has expired and would like to inform Pleasurecraft of your ownership for notiﬁ cation purposes in case of Service Updates, Recalls, etc., complete the section below and return by mail to PCM. PO Drawer 369, Little Mountain, SC 29075.

ENGINE MODEL: _________________________ ENGINE SERIAL NUMBER: _________________________ GEAR MODEL: _________________________ GEAR SERIAL NUMBER: _________________________

(New Owner) NAME: _____________________________________________________________________________ ADDRESS:______________________________________________________________________________________________________________ CITY,STATE,ZIP: ________________________________________________________________________________ DATE OF PURCHASE: ___________________________________________________________________________ (Previous Owner)NAME: _________________________________________________________________________ ADDRESS: _____________________________________________________________________________________ CITY,STATE,ZIP: ________________________________________________________________________________

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OPERATION AND MAINTENANCE LOG

Engine Port Drive Port Ignition Key Port Model and Serial # Stbd. Serial # Stbd. Number Stbd.

Fire Extinguisher Checked Batteries Tested

Gal of Qts of Oil Oil Check Lay Up Launch

Runs Made Date Fuel Port Stbd. Miles Hours Change Drive Date Date Remarks

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FORMS - 18

PROBLEM NOTIFICATION OR INFORMATION REQUEST FORM

IMPORTANT: All blanks MUST be completed to insure proper identiﬁ cation of your engine which is necessary to

properly understand your request. When completed, mail this form to: Pleasurecraft Marine

PO Box 369 Little Mountain, SC 29075

Engine Model Engine Serial Number Gear Serial Number

Owner Information

Name Telephone ( ) Address City State Zip Selling Dealer Dealers Address Date of Purchase Boat Make Length Type

Gentlemen, I would like to inform you of a problem I have experienced with the above engine. My problem is:

My boat is located at Address Telephone ( ) City State Zip Requestors Signature Date

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Pleasurecraft Engine Group 1737 Highway 76 East, Little Mountain SC 29075

PCM 2003 5.0L MPI, 2003 5.7L MPI, 2003 6.0L MPI, 2003 8.1L MPI (HO), 5.0L MPI Owner's Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual