PCM 2006 5.0L MPI, 2006 5.7L MPI, 2006 6.0L MPI, 2005 5.0L MPI, 2005 5.7L MPI Owner's Operation And Maintenance Manual

...

Download

OWNER’S OPERA TION

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 demonstration 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

2006 5.0L MPI

2006 5.7L MPI

2006 6.0L MPI

Part Number - L510010-06 Printed 03/06

TABLE OF CONTENTS

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

Registration Information (Warranty Registration Card is located at the back of this manual) 3-Year 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

2006 Model Identiﬁ cation / Advisory ELECTRONIC FUEL INJECTION INFORMATION

Electronic Fuel Injection System Power Reduction Mode OPERATING INSTRUCTIONS Electronic Speed Control 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

Checking Fluid Levels Lubrication

......................................................................................................................................... 29

................................................................................................................................ 9

............................................................................................................................... 9

................................................................................................................................... 9

......................................................................................................... 10-12

.................................................................................................................... 10

................................................................................................................... 11

.................................................................................................................................... 11

................................................................................................................. 11

............................................................................................................................... 12

............................................................................................................. 13-14

............................................................................................................................ 13

....................................................................................................................... 15

........................................................................................................ 16-20

..................................................................................................................... 16

.......................................................................................................................... 16

................................................................................................................................... 17

.......................................................................................................................... 19

................................................................................................................................. 20

................................................................................................................ 21

....................................................................................................................................... 21

.............................................................................................................................. 22

.............................................................................................................. 23

..................................................................................................................... 25

....................................................................................................................... 25

................................................................................................................ 25

........................................................................................................................ 26

.............................................................................................................. 26

............................................................................................................... 27-55

........................................................................................................................... 27

.................................................................................................................... 27-29

..................................................................................................... 4

..................................................................................... 5

...................................................... 6

.................................................................................. 13

..................................................................................................... 14

................................................................................ 15

.......................................................................................................... 15

................................................................................................ 18

.......................................................................................................... 20

............................................................................................................ 20

........................................................................................ 21-22

........................................................................................................ 24

....................................................................................... 26

........................ 3

L510010-06

TABLE OF CONTENTS

Electrical System Circuit Breaker(s) ..................................................................................................... 30

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

Primary Fuel Filter (FCC Screw-on Canister)

Primary Fuel Filter (FCC Clamp-on Canister) Servicing Fuel Pre-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 Recommissioning After Storage

TROUBLESHOOTING

WATER FLOW DIAGRAMS INSTRUMENTATION WIRING DIAGRAM

LITERATURE FORMS NOTES WARRANTY/REGISTRATION CARD

............................................................................................................................ 30

.................................................................................................................................... 31

......................................................................................................................... 42

.......................................................................................................................... 45

................................................................................................................. 46-49

...................................................................................................................... 53

........................................................................................................................ 58

........................................................................................................................ 60

.......................................................................................................................... 70

............................................................................................................................... 71-74

................................................................................................................................... 75

............................................................................................................. 30

...................................................................................... 30

......................................................................... 32

............................................................................................................. 33

................................................................................ 34

...................................................................................................... 35

.......................................................................................... 35

.............................................................................................. 36

....................... 37

............................................................................................................ 38

............................................................................................ 38

..................................................................................................................... 39

................................................................................. 40

................................................................................. 41

............................................................................................................. 42

................................................................................................................. 42

............................................................................................................. 43-44

............................................................................................................ 50

.............................................................................................................. 51

............................................................................................................. 53

..................................................................................................... 53

................................................................................................................... 54

................................................................................................... 55-57

................................................................................................ 58-61

.................................................................................................................. 59

................................................................................................... 61

.......................................................................................................... 62-64

................................................................................................... 66-68

..................................................................................... 69

L510010-06

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 web site at www. pleasurecraft.com.

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

INTRODUCTION - 1

L510010-06

INTRODUCTION - 1

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

3 Year Transferable Limited Warranty

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.

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, 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.

L510010-06

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.

L510010-06

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.

L510010-06

INTRODUCTION - 1

This Page Was

Intentionally

Left Blank

L510010-06

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.

L510010-06

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.

L510010-06

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.

L510010-06

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)

2. Can Buoy: This buoy indicates the port

3. Lighted Buoy (RED): This buoy has a

4. Lighted Buoy (GREEN): This buoy has

1. Nun Buoy: This buoy indicates the 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.

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.

ﬂ ashing red light. It indicates the starboard side of the channel when returning from sea.

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.

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.

L510010-06

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 50 degreesF

5W-30Below 50 degreesF

MARINEGEAR OIL RECOMMENDATIONS AllPCM, Warner andHurth Transmissions: DextronIII

Important!See yours ownersmanual to insure thatspecifications for your enginehave not changedor been ommitted fromthe specifications listed.

ENGINES

1. ENGINE SPECIFICATION DECAL

MAKE MODEL SERIAL FIRING ORDER

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

LITTLE MOUNTAIN,SC 29075

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

ELECTRICALSPECIFICATIONS 12Volts - NegativeGround

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 25 HOURSOF OPERATIONAND EVERY100 HOURS OR12 MONTHS,WHICHEVER OCCURS FIRST. IMPORTANTNOTE: WARRANTYIS VOID IF MAINTENANCEAND LUBRICATIONINSTRUCTIONS PERPCM MANUALARE NOT FOLLOWED.

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:

L510010-06

ENGINE IDENTIFICATION - 3

2006 MODEL IDENTIFICATION / ADVISORY

MODEL 0 2 - 6 0 0 V - 0 1 SERIAL 460000

1st - 2nd Space: MANUFACTURING CODE

rd - 5th

Space: ENGINE CODE

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

PCM

*SERIAL NUMBER I.D.*

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

Space: DRIVE CONFIGURATION

6 blank - Direct Drive V - V-Drive

th - 8th

Space: SPECIFICATION CODE

L510010-06

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.

L510010-06

OPERATING INSTRUCTIONS - 5

ELECTRONIC SPEED CONTROL (IF EQUIPPED)

This engine is equipped with a Digital Throttle Control (DTC) system. The system uses a throttle cable connected between the throttle handle and a Throttle Control Positioning (TCP) sensor located on the engine. The Throttle Control Positioning sensor provides throttle position information to the engine management system which, in turn, electronically controls engine throttle movement.

This boat may also be equipped with an electronic speed control system for skiing, wake boarding, or cruise control. When the boat is operated in a speed control mode, the operator may not have full control of the throttle until the speed control system is deactivated.

Example: If the speed control system is engaged at 32 mph, the throttle handle may be “dead” when trying to accelerate above 32 mph. The speed control system would need to be disengaged, then the operator will gain full control of the boat speed.

Refer to your Boat Manufacturers Owners/ Operational manual for speciﬁ c operation and troubleshooting information for your speed control system.

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 may 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.

L510010-06

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)

OPERATING INSTRUCTIONS - 5

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

7. Fuel Level Gauge - indicates the fuel tank level

8. Check Engine Lamp - indicates a problem with the engine control system

100

170

OIL

200

TEMP

CHECK

ENGINE

VOLT

1/2

FUEL

TAC H

L510010-06

OPERATING INSTRUCTIONS - 5

STARTING ENGINE (FUEL INJECTED ENGINES)

WARNING

Before starting engine, ventilate the engine compartment by operating the bilge blower for a minimum of ﬁ ve minutes to remove any gas fumes from the engine compartment. If the boat is not equipped with a blower, open the engine compartment hatches to ventilate and leave open while starting engine.

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

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

• Exhaust system for leaks and tightness of the clamps

• Battery connections and water level in battery cells

• Accessory drive belt(s)

• Cooling system for leaks. If equipped with freshwater 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.

L510010-06

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.

Figure 5-2 Shift Control

L510010-06

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.

L510010-06

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).

L510010-06

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 Preferred Maximum

MP 5.0L 4600 4800 5000

MP 5.7L 4800 5000 5200

MP 6.0L 4800 5200 5300

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 a RPM “REV LIMIT” in order to prevent the engine from over-revving.

L510010-06

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.

CAUTION

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

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 should 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 remaining 20 hours of break in period, the engines can be run at cruise speeds that are approximately 75-80% of the wide open throttle RPM, occasionally varying the cruise speed by 100 RPM.

• 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.

L510010-06

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.

• Replace 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.

L510010-06

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. 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.

L510010-06

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 “SM”

Below 50˚F SAE 5W-30 “SM”

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

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

PCM V-Drive Mobiltrans SHC 50 Transmissions Synthetic Transmission Lubricant

Walters “V”-Drive SAE 30

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

L510010-06

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.

L510010-06

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.

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. Wipe the dipstick off with a clean cloth. Re-insert the dipstick to the threads (do not screw the dipstick in) and remove the dipstick. 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. 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.

PCM 1.23:1 TRANSMISSION

SHIFT LEVER

DIPSTICK

FULL MARK

5. Replace the dipstick and tighten securely.

HURTH TRANSMISSION

SHIFT LEVER

DIPSTICK

MAX

MIN.

Figure 11-2A Transmission Dipstick and Location

Figure 11-2 Transmission Dipstick and Location

L510010-06

ENGINE MAINTENANCE - 11

PCM Power-Plus V-Drive Transmission

WARNING

Do not attempt to remove the transmission drain/ ﬁ ll plug while the engine is running or while the transmission is hot. Hot transmission ﬂ uid could be sprayed from the hole.

All PCM Power-Plus “V” Drive transmissions are designed to be ‘Maintenacne Free’. Inspect ﬂ uid level after the ﬁ rst 25 hours of use and annually thereafter. Fluid should only be changed if evidence of contamination is present. Use Mobiltrans SHC 50 synthetic transmission lubricant.

1. Remove the drain/ﬁ ll plug from the transmission. Observe the ﬂ uid level.

2. The ﬂ uid level should be at the bottom of the threaded hole. If low, add the speciﬁ ed ﬂ uid through the threaded hole to the proper level.

NOTE: The transmission ﬂ uid is a very high viscosity, to

make adding ﬂ uid easier, remove both ﬁ ll plugs.

3. Replace the drain/ﬁ ll plug(s) and tighten securely.

LUBRICATION

Throttle Cable

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

BALL JOINT

CABLE

CLIP

LUBRICATION

POINTS

Figure 11-3 Typical Throttle Cable

Shift Cable

Oil Fill/Drain

Plug

POWER PLUS

E G

1.48

Raw Water Drain Plug

Figure 11-2B Transmission Service Location

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

Oil Fill/Drain

Plug

LUBRICATION

POINTS

Figure 11-4 Typical Shift Cable

L510010-06

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.

WARNING

Always disconnect the battery cables from the battery, when servicing the electrical system, to prevent personal injury and to prevent damage to the electrical system components.

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.

L510010-06

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 the 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.

IMPORTANT: Your engine is designed to work with

the standard electronics installed in your boat. If you add other electrical components or accessories, you could change the way the fuel injection controls your engine or the overall electrical system functions. Before adding electrical equipment, consult your dealer. If you don’t, your engine may not perform properly.

CAUTION

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

L510010-06

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 check condition of zinc pencil every 30 days. Replace if more than 50% missing with Crusader Part #10972.

P/N 23627

ZINC

ANODE

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

Exchanger (6.0L)

L510010-06

CHECKING COOLANT LEVEL

ENGINE MAINTENANCE - 11

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.

Degas Bottle

The “see-through” degas bottle is connected to the heat exchanger by a small hose. The degas 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 bottle when the system cools. Add speciﬁ ed coolant as required.

PRESSURE

DEGAS

BOTTLE

Figure 11-7 Checking Coolant Level (6.0L)

CAP

L510010-06

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

L510010-06

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.

WARNING

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 the 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.

ENGINE MAINTENANCE - 11

WARNING

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:

Remove large HOSE, or DRAIN PLUG (if equipped)

Figure 11-9 Draining Engine Circulating Pump (5.0/5.7L)

− 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.

L510010-06

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.

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.

ANTIFREEZE

SOLUTION

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

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.

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.

L510010-06

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

ENGINE MAINTENANCE - 11

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.

4. Start the engine and inspect for leaks.

HEAT

EXCHANGER

PLATE

COOLANT

DRAIN PLUG

RAW WATER

DRAIN PLUG

GASKET

BOLT

Figure 11-11 Heat Exchanger and End Plate Removal

(Typical)

L510010-06

ENGINE MAINTENANCE - 11

FUEL SYSTEM DESCRIPTION

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.

Fuel Control Cell (FCC) Fuel System

The Fuel Control Cell (FCC) eliminates vapor lock and air ingestion caused by fuel tank slosh, and provides the necessary ﬁ ltration and water separation.

The FCC system 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, high-volume 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 may be located on the fuel rail or inside the FCC bowl, 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 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.

L510010-06

FUEL

CONTROL

CELL

ENGINE MAINTENANCE - 11

FUEL

SUPPLY

LINE

FUEL

RETURN

LINE

5.0/5.7L ONLY

TO FUEL TANK

FUEL

PRE-FILTER

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.

FILTER

ELEMENT

L510010-06

ENGINE MAINTENANCE - 11

Primary Fuel Filter (FCC Screw-on Canister)

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.

Filter Element Replacement, ENGINE OFF

FCC SERVICE KIT#: RP080026

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 viewed 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

PRESSURE

REGULATOR

FUEL

PUMP

"O"- RING

FILTER

FUEL

DRAIN

FUEL

BOWL

FUEL

PUMP

Figure 11-13 Fuel Control Cell (FCC) - Screw-on

Canister (Typical)

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.

8. Lubricate the new O-ring with a fuel resistant O-ring lubricant 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.

L510010-06

Primary Fuel Filter (FCC Clamp-on Canister)

ENGINE MAINTENANCE - 11

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. 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.

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.

Filter Element Replacement, ENGINE OFF

FCC SERVICE KIT#: RP080026

1. Disconnect the two-wire electrical connector.

2. 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. Remove the canister retaining clamp.

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

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. Visually inspect all internal components, i.e. hoses, wires, etc.

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

8. Using a pick made of soft material, such as a toothpick, remove the old O-rings from the FCC head.

6.0L 5.0/5.7L

O-RINGS

FUEL

PRESSURE

REGULATOR

FUEL

DRAIN

FUEL PUMP

FUEL

FILTER

RETAINING

FUEL

BOWL

CLAMP

Figure 11-14 Fuel Control Cell (FCC) - Clamp-on

Canister (Typical)

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

9. Install the new O-rings in the same location. Lubricate the new O-rings with a fuel resistant O-ring lubricant.

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

11. Install and tighten the 7/16” plug into the cansister.

12. Install the canister ﬁ rmly back onto the FCC head.

13. Reinstall the retaining clamp and tighten securely.

14. Reconnect the two-wire electrical connector.

15. 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.

16. 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.

L510010-06

ENGINE MAINTENANCE - 11

Servicing the Fuel Pre-Filter

The frequency of 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

Filter Element Replacement, ENGINE OFF

PRE-FILTER SERVICE KIT#: RP077014

The pre-ﬁ lter assembly does not need to be removed from the low pressure fuel pump to service the ﬁ lter element.

1. Disconnect the fuel supply line from the pre-ﬁ lter ﬁ tting and block the line to prevent fuel spillage.

2. Secure the ﬁ lter by the wrench ﬂ ats at the low pressure fuel pump.

3. Remove the ﬁ lter end cap.

4. Remove the old ﬁ lter and seal.

5. Install the new ﬁ lter and seal.

6. Re-install the ﬁ lter end cap and tighten securely.

7. Re-install the fuel supply line and tighten retaining clamp securely.

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

FLAME ARRESTOR

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

Loosen the fastener(s) 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 fastener(s) securely.

FLAME

ARRESTOR

FASTENERS

FLAME

ARRESTOR

THROTTLE

BODY

Figure 11-15 Flame Arrestor - 5.7L (Typical)

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.

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.

L510010-06

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.

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).

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:

• 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

Alternator

ENGINE MAINTENANCE - 11

Figure 11-17 Belt Tensioner (6.0L)

DRIVE BELT REPLACEMENT (6.0L)

6.0L SERPENTINE BELT #: R066027

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.

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.

Belt

Tensioner

Circulation

Idler

Pump

Crankshaft

Pulley

Figure 11-16 6.0L Accessory Drive Belt Conﬁ guration

Raw Water

Pump

SERVICING RAW WATER PUMP IMPELLER (6.0L)

6.0L IMPELLER KIT #: RP061022

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 11-20) 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.

Torque the raw water pump housing attaching bolts to 8.5-9 ft.lbs. (11.5-12 N-M), when re-installing the impeller.

L510010-06

ENGINE MAINTENANCE - 11

5.0/5.7L ACCESSORY DRIVE BELT

The PCM 5.0/5.7L engines use a single serpentine belt to drive the engine water circulation pump, sea-water pump and the alternator.

WARNING

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:

• 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

Belt

Tensioner

Figure 11-19 Belt Tensioner (5.0/5.7L)

DRIVE BELT REPLACEMENT (5.0/5.7L)

5.0/5.7L SERPENTINE BELT #: R066028

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.

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.

Circulation

Pump

Crankshaft

Pulley

Raw Water

Pump

Figure 11-18 5.0/5.7L Accessory Drive Belt

Conﬁ guration

Alternator

SERVICING RAW WATER PUMP IMPELLER (5.0/5.7L)

5.0/5.7L IMPELLER KIT #: RP061022

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 11-22) 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.

Torque the raw water pump housing attaching bolts to 8.5-9 ft.lbs. (11.5-12 N-M), when re-installing the impeller.

L510010-06

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 QUICK-DRAIN

HOSE

CONTAINER

The transmission oil change should be performed by an authorized PCM dealer, at speciﬁ ed intervals. Transmission ﬂ uids should be removed through a copper tube, that extends to the bottom of the transmission case, using a suction/vacuum type ﬂ uid extractor.

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, locate the oil pan quick drain hose and thread the hose through the boat’s drain plug hole. (Figure 11-24). Remove the cap from the end of the quick-drain hose and insert the discharge hose into a suitable container. Allow the oil from the engine to drain until the crankcase is empty. Reinstall the cap onto the quick-drain hose and pull the hose back through the drain and secure the hose at the engine.

Figure 11-20 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 11-25).

OIL

FILL

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 11-21 Engine Oil Fill (5.7L)

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.

L510010-06

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: For PCM Power-Plus and Walters V-Drive applications, adjust the engine and transmission mounts to achieve alignment. The V-Drive mounts are for support of the VDrive unit and are not used to achieve proper alignment.

REMOVE

MOUNT BOLTS

TRUNNION

BOLT

ECR

PLEASUR

INE GROU

ENG

ER PLUS

POW

1.48

E IN USA

ENGINE ALIGNMENT

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 (Figure 11-23).

Figure 11-22 PCM V-Drive

V-DRIVE ALIGNMENT

The V-Drive support mounts must be removed before performing the engine alignment.

• For the PCM V-Drive, loosen the trunnion bolt on the mount, then remove the bolts used to attach the mount to the CVD mounting bracket. Slide the mount away from the bracket. Refer to Figure 11-22.

• For the Walters V-Drive, loosen the trunnion bolt on the mount, then remove the bolts used to attach the mount to the V-Drive. Slide the mount away from the V-Drive unit.

Perform the Engine Alignment as outline in the following steps. When you have completed the alignment you will need to re-install the mounts onto the V-Drive unit. The V-Drive mounts may need to be adjusted so there is no tension on the mounting bolts as they are re-installed. Retighten the trunnion bolts to complete the V-Drive alignment.

Figure 11-23 Shaft Mating Surface Check

2. Center the propeller shaft in the shaft log as follows: (Figure 11-24)

• 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.

L510010-06

ENGINE MAINTENANCE - 11

.003 INCH

(0.07 mm)

FEELER GAUGE

TRANSMISSION

OUTPUT FLANGE

Figure 11-24 Centering Prop Shaft

3. Check that the coupling center lines align by butting the propeller shaft coupling against the transmission coupling (Figure 11-25). The shoulder on the propeller shaft coupling face should engage the recess on the transmission coupling face, with no resistance.

PROPELLER

SHAFT

COUPLING

FLANGE

STRAIGHT

EDGE

Figure 11-26 Angular Alignment

OFFSET ALIGNMENT:

4. If the coupler center lines are not aligned, adjust the mounts as follows:

• UP or DOWN OFFSET 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.

OFFSET

MISALIGNMENT

PERFECT ALIGNMENT

COUPLING FACES ARE PARALLEL

WITH DISTANCE BETWEEN FACES

EXACTLY THE SAME AT ALL POINTS

ANGULAR

MISALIGNMENT

Figure 11-25 Shaft Mating Surface Check

IMPORTANT: Offset misalignment conditions must be corrected prior to checking for angular misalignment.

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 11-26).

IMPORTANT: For Offset Alignment, both front mounts (or rear mounts) must be turned equally or angular misalignment will occur.

LOCKING

NUT

ADJUSTING

NUT

Figure 11-27 Mount Adjustment

L510010-06

ENGINE MAINTENANCE - 11

• 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. After adjustment is complete, tighten all bolts.

LOCKING

NUT

Figure 11-28 Mount Adjustment

IMPORTANT: The large diameter of the mount trunnion MUST NOT extend over 1.750 in. (44.45 mm), from the mounting brackets on any of the mounts; and a sufﬁ cient amount of the trunnion must remain in the mount to be secured by the trunnion locking bolt.

ADJUSTING

BOLT

.003 INCH (0.07 mm)

FEELER GAUGE

PROPELLER

SHAFT

COUPLING

FLANGE

Figure 11-30 Angular Alignment

5. Check for any angular misalignment. Hold coupling faces tightly together by hand and check for a gap between the coupling faces, with a

0.003 in. (0.07 mm) feeler gauge, at 90-degree intervals. (Figure 11-30).

TRANSMISSION

OUTPUT FLANGE

STRAIGHT

EDGE

1.750 in. MAX (44.45 mm)

TRUNNION

BOLT

Figure 11-29 Engine Extension

Figure 11-31 Angular Alignment Check

IMPORTANT: Angular misalignment conditions may require adjustment of one front mount, both front mounts, the trunnions, or any combination. Figure 11-31 (Angular Alignment Check) and the following table are to assist in the alignment process.

L510010-06

Angular Misalignment Front Mount Adjusted

A Both

B Trunnion

LC R

RC L

• To adjust a corner of the engine up or down, 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: If a “pinch” occurs in the “A” quadrant (Figure 11-31), correcting the condition will require an equal adjustment on the front mounts. If a “pinch” occurs in the “C” quadrant, an adjustment will be made on the opposing front mount. If a “pinch” occurs in the “B” quadrant, a trunnion adjustment is required.

ENGINE MAINTENANCE - 11

• To move the engine left or right, 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. After adjustment is complete, tighten all bolts.

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)

L510010-06

ENGINE MAINTENANCE - 11

ENGINE MAINTENANCE LOG

Operating Date Maintenance/Repair Hours

L510010-06

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 - Inspect/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

L510010-06

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) X

Fuel Filters - Service or replace O O O

Transmission - Change ﬂ uid (B) and clean strainer, if equipped O O

‘V’-Drive Transmissions - Change ﬂ uid (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

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)

(X)

Notes:

(X) Denotes service to be performed by the owner/

operator

(O) Denotes service to be performed by an authorized

PCM Engines dealer

(A) Use SAE 30 engine oil

(B) All PCM, Velvet Drive and Hurth transmissions - Use

Dexron III automatic transmission ﬂ uid

designed to be ‘Maintenacne Free’. Inspect ﬂ uid level after the ﬁ rst 25 hours of use and annually thereafter. Fluid should only be changed if evidence of contamination is present. Use Mobiltrans SHC 50 synthetic transmission lubricant.

All Walters “V” Drive transmissions - Use Exxon

Spartan EP-68 or SAE 30 engine oil

All Velvet “V” Drive transmissions - Use Dexron III

automatic transmission ﬂ uid

(D) Use WD-40 penetration oil or equivalent

L510010-06

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

120 days (whichever occurs ﬁ rst). In salt-water areas, 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).

Requires more frequent inspection if used in extremely

salty, polluted or mineral-laden waters.

See COOLANT SPECIFICATIONS.

ENGINE MAINTENANCE - 11

VISUAL INSPECTION

It is important for the owner/operator to visually inspect

the complete engine assembly at regular intervals. Most

often, costly repairs can be avoided if potential problems

are corrected before there is a failure.

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

Crankcase Oil Capacity W / New Filter 4 Quarts (3.8 L)

Fresh Water Cooling System Capacity 18 Quarts (17.03 L) 18 Quarts (17.01 L)

Touch up scratches, nicks and corrosion damage to the exterior ﬁ nish of the engine. Spray paint may be obtained from your local PCM Engines dealer.

Protect engine ﬁ nish from corrosion by periodically spraying the engine exterior ﬁ nish with a rust preventative oil (such as WD-40).

5 Quarts (4.75 L)1

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

Mobiltrans

PCM Power-Plus 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 capac-

ity needed for transmission cooler and oil lines. Always use the dipstick to determine the exact quantity of oil required. Add the correct amount of oil to ﬁ ll to the “FULL” mark on the oil level dipstick.

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

1,2

1.5 Quarts (1.42 L) SHC 50 synthetic

L510010-06

ENGINE MAINTENANCE - 11

FILTER REQUIREMENTS

Description Part No.

Oil Filter (remote-mounted) R077001

Fuel Pre-Filter Element RP077014

Fuel Control Cell (FCC) Fuel Filter Element RP080026

L510010-06

ENGINE SPECIFICATIONS - 12

‘06 PCM MASTER ENGINE SPECIFICATIONS

MODEL MP 5.0L MP 5.7L MP 6.0L (Horsepower) (275 HP) (330 HP) (375 HP)

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

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

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

Compression Ratio 9.4:1 9.4:1 9.4:1

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

WOT Operating RPM 4600-5000 4800 - 5200 4800 - 5300 Preferred WOT RPM 4800 5000 5200

Cruising RPM (Max) 3800 4000 4000

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

Oil Pressure @ 25 - 60 psi 25 - 60 psi 25 - 80 psi 2000 RPM (172 - 414 kPa) (172 - 414 kPa) (172 - 552 kPa)

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

Spark Plug P/N R030010 R030010 R030011 Spark Plug Gap 0.060 in. 0.060 in. 0.060 in.

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

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

FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 160˚F (61.7˚C)

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

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

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

Ignition Timing Not Adjustable Not Adjustable Not Adjustable

CAM Retard 43-47 degrees 43-47 degrees Not Adjustable

Battery Rating 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 120 Ah 120 Ah 120 Ah

L510010-06

ENGINE SPECIFICATIONS - 12

‘06 PCM MASTER FUEL PRESSURE SPECIFICATIONS

MODEL MP 5.0L MP 5.7L MP 6.0L (Horsepower) (275 HP) (330 HP) (375 HP)

MY ‘03 Only Fuel Pressure 57-62 psi @ WOT 57-62 psi @ WOT 57-60 psi @ WOT STD. FCC

MY ‘04 and newer Fuel Pressure - FCC 57-62 psi Returnless to Rail (WOT)

Fuel Pressure - LPFP 4 - 7 psi 4 - 7 psi 4 - 7 psi ALL ENGINES (WOT) (WOT) (WOT)

IMPORTANT: FUEL PRESSURE MEASUREMENT MUST BE MADE WITH THE

ENGINE UNDER LOAD.

‘06 PCM MASTER WARNING/ALARM SPECIFICATIONS

MODEL MP 5.0L MP 5.7L MP 6.0L (Horsepower) (275 HP) (330 HP) (375 HP)

Coolant 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) Over-Temperature Water Temp Lamp Water Temp Lamp Water Temp Lamp Sensor Power Reduction Power Reduction Power Reduction

Transmission 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F Over-Temperature Gen. Warning #1 Gen. Warning #1 Gen. Warning #1 Switch Trans Temp Lamp Trans Temp Lamp Trans Temp Lamp (Optional) Power Reduction Power Reduction Power Reduction

Low Oil < 10 psi < 10 psi < 10 psi Pressure Gen. Warning #2 Gen. Warning #2 Gen. Warning #2 Switch Oil Pressure Lamp Oil Pressure Lamp Oil Pressure Lamp

Exhaust 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F Over-Temperature M.I.L. - DTC 81 M.I.L. - DTC 81 M.I.L. - DTC 81 Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp (Optional)

NOTE: ‘Power Reduction” mode limits engine RPM to 2000. Above 2000 RPM the ECM will disable half of the fuel injectors. Reducing engine RPM below 1200 will restore normal engine operation until RPM exceeds 2000. Depending upon Instrument Panel conﬁ guration, individual warning lights, Check Engine/Check Gauges indicator, and/or an audible alarm buzzer may light/sound when a malfunction occurs.

L510010-06

ENGINE SPECIFICATIONS - 12

5.0 / 5.7 Liter

LH ROTATION

FRONT

6.0 Liter

LH ROTATION

FRONT

DISTRIBUTOR

Rotation

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 (375 HP)

Spark Plug Type R030010

(1.52 mm) (1.52 mm)

Not Adjustable Not Adjustable

MP 5.0L (275 HP)

Model

Spark Plug Gap

Ignition Timing

0.060 in. 0.060 in.

Fixed, Fixed,

FIRING ORDER:

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

R030011

Firing Order

(LH Rotation) (LH Rotation)

CAM Retard 43-47 degrees

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

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

Not Adjustable

L510010-06

OUT-OF-SEASON STORAGE - 13

ENGINE STORAGE

IMPORTANT: These services 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 placed 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.

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.

5. Turn off the ignition and remove the spark plugs. Use an aerosol-type fogging solution and spray a sufﬁ cient amount into each cylinder. (Spray 5 seconds per cylinder, minimum.) Turn the crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders.

NOTE: If you are using a bulk type preservative oil, pour approximately one (1) teaspoon full of oil into each cylinder, through the spark plug hole, then turn the crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders.

6. Install the spark plugs and connect the spark plug wires.

NOTE: It will be necessary to remove the spark plugs and spin the engine to eliminate excess oil prior to restarting after the storage period.

7. Remove and 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.

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

WARNING

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).

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

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.

4. Restart the engine and allow it to idle for 5 minutes.

On fuel injected engines, you MUST bleed off fuel pressure before proceeding. Failure to do so may cause personal injury.

9. Remove, empty and clean the fuel ﬁ lter shell. Reinstall with a new fuel ﬁ lter and gasket. Refer to Engine Maintenance for ﬁ lter replacement procedures.

NOTE: DO NOT re-use old fuel ﬁ lter components. Always replace with new fuel ﬁ lter and gasket.

L510010-06

DRAINING INSTRUCTIONS

CAUTION

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:

OUT-OF-SEASON STORAGE - 13

• 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 Cooler - one drain plug.

• (If Equipped) PCM V-Drive Transmission

- one drain plug.

2. Remove the hose from the inlet side of the seawater 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. Remove the raw water pump impeller. (See ENGINE MAINTENANCE) If inspection proves the impeller to be in good condition, store it in an accessible spot for re-installation at the end of the storage period. A damaged or badly worn impeller should be discarded and a new one installed at the end of the storage period.

NOTE: Removal of the impeller during storage will prevent the impeller vanes from drying and taking a permanent “set”.

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 DRAIN PLUG

(as equipped)

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

ENGIN

1.48

ADE

9/16”

Hex Key

Socket

Remove Raw Water

Drain Plug

Figure 13-2A Draining PCM V-Drive Transmission

6. Loosen the engine alternator and raw water pump drive belt(s).

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.

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

L510010-06

OUT-OF-SEASON STORAGE - 13

8. 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.

9. 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.

DRAINING INSTRUCTIONS

CAUTION

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.

2. Remove the hose from the inlet side of the seawater pump.

3. Remove the hose from the outlet side of the seawater pump.

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

NOTE: Removal of the impeller during storage will prevent the impeller vanes from drying and taking a permanent “set”.

5. 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.

6. Loosen the engine alternator and raw water pump drive belt(s).

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

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 the ENGINE MAINTENANCE section for testing alkalinity, draining and reﬁ lling procedures of the Fresh Water Cooling System, as required.

IMPORTANT: Drain the sea-water section of the cooling system only.

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

• Transmission Cooler - one drain plug

• (If Equipped) PCM V-Drive Transmission

- one drain plug.

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.

• 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.

L510010-06

RECOMMISSIONING AFTER STORAGE

IMPORTANT: These services should be performed by an Authorized PCM Dealer.

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

1. Assemble the raw water pump and reinstall on the engine.

2. 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.

OUT-OF-SEASON STORAGE - 13

CAUTION

Failure to remove the excess storage oil from the engine’s cylinders can cause hydrostatic locking to occur, and severe damage to the engine.

8. Before starting the engine, be sure there is not an excess amount of storage oil left in the cylinders. Remove the spark plugs. Disable the fuel pumps and ignition high voltage spark by removing the MEFI System Relay. Using rags draped over the exhaust manifolds or some other suitable material or method, create a deﬂ ector or catcher for the oil that will be sprayed from the spark plug holes. Turn the ignition switch to the start position and rotate the engine three (3) or four (4) times.

9. Reinstall the MEFI System Relay.

10. Install the spark plugs and connect the spark plug wires.

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.

3. 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.

4. Readjust alternator and water pump drive belt tension.

5. Check engine alignment.

6. Check engine and transmission oil levels.

7. Check engine mount fasteners.

11. Open the fuel shut-off valve (if equipped).

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

13. Refer to the Engine Maintenance section and perform the Priming the Fuel System instructions.

CAUTION

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

14. Open the seacock before starting the engine.

15. 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.

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

L510010-06

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.

L510010-06

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.)

L510010-06

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”).

L510010-06

m (15 lb ft)

Knock Sensor

Torque 20 N

WATER FLOW DIAGRAMS - 15

= RAW WATER FLOW

IMPORTANT: Accessory (i.e.

heater, hot water tank) Hook Up

Location 1 - Water OUT to

heater or hot water tank. T-Fitting

required at temp. sender location.

= Drain Locations

Location 2 - Water RETURN

from heater or hot water tank.

Fitting at circulating pump.

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

L510010-06

WATER FLOW DIAGRAMS - 15

IMPORTANT: Accessory (i.e.

heater, hot water tank) Hook Up

Location 1 - Water OUT to

heater or hot water tank. T-Fitting

required at temp. sender location.

Location 2 - Water RETURN

from heater or hot water tank.

Fitting at bottom of heat

exchanger OR circ. pump.

= FRESH WATER FLOW

= RAW WATER FLOW

= Drain Locations

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

L510010-06

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.

Location 1 - Water OUT to heater or hot water tank

Location 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)

=RAWWATERFLOW

= FRESH WATER FLOW

= 7 Drain Locations

L510010-06

WATER FLOW DIAGRAMS - 15

DRAIN

= Optional Drain Kit

The drain kit does not ensure that all of the water will drain out of the system. Engine angle, routing of drain hose, and restricted drain fittings are some things that could prevent all of the water from draining completely.

Figure 15-4 Water Drain kit - Optional (6.0L)

L510010-06

INSTRUMENTATION WIRING DIAGRAMS - 16

WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS

NUMBER NAME WIRE COLOR

1. GROUND BLACK

2. TACHOMETER GRAY

3. COOLANT TEMP. TAN

4. BUZZER TAN/BLACK

5. IGNITION PURPLE/WHITE

6. BATTERY RED/WHITE

7. STARTER YELLOW/RED

8. OIL PRESSURE LT. BLUE

9. MIL BROWN/WHITE

10. SERIAL DATA 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

ENGINE

HARNESS

ENGINE HARNESS

SPEED CONTROL

WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS

NUMBER NAME WIRE COLOR

A. TACHOMETER GRAY B. VAR. GOVERNOR YELLOW C. STATUS LAMP WHITE/RED D. CRUISE REQUEST WHITE/ORANGE

E. - -

F. TCP SENSOR BLACK/GRAY G. - H. - -

J. - K. PERFECT PASS GROUND BLACK

Figure 16-1 Typical Instrumentation Wiring

INTERFACE CONNECTOR

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

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

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

CAUTION

L510010-06

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.

L510010-06

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 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. A step-by-step procedure for pre-delivery

can be found in Course 1 of the PCM E-Train Program. 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.

ENGINE MODEL: ENGINE SERIAL:

TRANS. SERIAL: ENGINE HOURS:

HULL SERIAL #:

Pre-Delivery Checklist

Check for Bulletins

Engine Oil: Check

Drive Lube: Check

Battery Rating, Charge, and Level: Check

Control Adjustments: Conﬁ rm Proper Operation

Gauges: Check for Proper Operation

Type Information

To Prevent

Processing Delay

Record Propeller Size, Rotation and WOT WOT RPM_________Diameter_________ Pitch_________Rotation__________

Record Fuel Pressure, Idle ______ Record Fuel Pressure, WOT ______

Dealer Reviewed Warranty with Owner

DATE OF SALE (2ND Owner) / /

Belt and Pulley: Inspect for Damage

All Drain Plugs: Conﬁ rm Proper Installation

All Fuel Lines: Conﬁ rm No Leaks

All Oil Lines: Conﬁ rm No Leaks

All Water Lines: Conﬁ rm No Leaks

Electrical Wiring: Check for Proper Installation

Trouble Codes Checked Trouble Codes Cleared

DATE OF SALE (1st Owner/1st Operator)

/ /

(New Owner) (Previous Owner) NAME: NAME:

ADDRESS: ADDRESS:

CITY,STATE, ZIP CITY,STATE, ZIP

I hereby certify the pre-delivery checklist on engine #

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

and have corrected any abnormality revealed by this inspection.

L510010-06

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:

2002 ** 3 years, unlimited hours, Ford and GM. 3 years, unlimited hours Transmission

2003 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

2004 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

2005 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

2006 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

Base Engine 1 year, 200 hours with exclusions.

Note: ** 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: _________________________

TRANS. MODEL: _________________________

TRANS. SERIAL NUMBER: _________________________

(New Owner) NAME: _____________________________________________________________________________

ADDRESS:______________________________________________________________________________________________________________

CITY,STATE,ZIP: ________________________________________________________________________________

DATE OF PURCHASE: ___________________________________________________________________________

(Previous Owner)NAME: _________________________________________________________________________

ADDRESS: _____________________________________________________________________________________

CITY,STATE,ZIP: ________________________________________________________________________________

L510010-06

FORMS - 18

OPERATION AND MAINTENANCE LOG

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

Fire Extinguisher Checked Batteries Tested

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

Gal of Qts of Oil Oil Check Lay Up Launch

L510010-06

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 Drawer 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

L510010-06

NOTES - 19

L510010-06

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

PCM 2006 5.0L MPI, 2006 5.7L MPI, 2006 6.0L MPI, 2005 5.0L MPI, 2005 5.7L MPI Owner's Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual