PCM EX343 MPI (2011), Catanium CES 6.0L ZR450 (2011), ZR409 MPI (2011), Catanium CES EX343 (2011), Catanium CES HO303 (2011) Owner's Operation And Maintenance Manual

OWNER’S OPERATION

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MAINTENANCE MANUAL

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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 30 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 year of manufacture PCM engines: Year Model 2011 HO303 MPI 2011 EX343 MPI 2011 ZR409 MPI *2011 Catanium™ CES HO303 *2011 Catanium™ CES EX343 *2011 Catanium™ CES 6.0L ZR409 *2011 Catanium™ CES 6.0L ZR450

* PCM’s Catanium™ Clean Emission System is available to reduce emissions without diminishing performance. Catanium™ CES is patented catalyst technology which uses precious metals to create clean emissions and greatly reduce dangerous carbon monoxide gases.

Part Number - L510010-11 Printed 04/11

PROPOSITION 65

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Part Number - L510010-11 Printed 04/11

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................................... 3-9

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

Federal/California Emission Control Warranty Statement

PCM Inboard Marine Engine General Emissions Warranty Coverage

Safety Information Replacement Parts Safety Warnings

BOATING RESPONSIBILITIES

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 Engine Model Identiﬁ cation / Advisory

ELECTRONIC FUEL INJECTION INFORMATION

Electronic Fuel Injection System

OPERATING INSTRUCTIONS

Engine Alarm System Instrumentation Electronic Speed Control Starting Engine (Fuel Injected Engines)

Shifting Transmission

Stopping Engine Freezing Temperature Operation Operation in High Debris Areas PCM Basic Cruise Speed Control System

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

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TABLE OF CONTENTS

Electrical System Relay and Fuse Block ............................................................................................... 32

Electrical System Fuses Boat’s 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 Clamp-on Canister) Servicing Fuel Pre-Filter

Priming Fuel System

Flame Arrestor Accessory Drive Belt Servicing Raw Water Pump Impeller

Changing Oils

Engine Alignment Engine Maintenance Log

Maintenance Schedule

Visual Inspection

Engine Fluid Capacities Transmission Fluid Capacities

Filter and Accessory Requirements

ENGINE SPECIFICATIONS OUT-OF-SEASON STORAGE

Engine Storage Draining Instructions

Battery Storage Recommissioning After Storage

TROUBLESHOOTING

RAW WATER FLOW DIAGRAMS

HEATER CONNECTIONS INSTRUMENTATION WIRING DIAGRAM

LITERATURE FORMS NOTES WARRANTY/REGISTRATION CARD

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L510010-11

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

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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 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 Federal/California Emissions Warranty and Federal/California Emissions Control Warranty Statement is a separate document included in this

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

Manual. Any questions concerning the Emissions Warranty can be obtained by calling 1-803-345-0050.

INTRODUCTION - 1

FEDERAL/CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The Environmental Protection Agency (EPA), California Air Resources Board (CARB) and Pleasurecraft Marine Engine Co. (hereinafter “Pleasurecraft”) are pleased to explain the emission control system warranty on your inboard marine engine manufactured after January 1, 2008 for CARB and after January 1, 2011 for EPA. Federally, new inboard engines must be designed, built and equipped to meet EPA and CARB’s emissions and 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 inboard marine engines manufactured after January 1, 2008 for CARB and after January 1, 2011 for EPA are warranted for 3 years or 480 hours, whichever ﬁ rst occurs.

However, warranty coverage based on the hourly period is only permitted for engines that are equipped with appropriate hour meters as deﬁ ned in § 2441(a)(13) or their equivalent. If any emission related part on your engine is defective under warranty, the part will be repaired or replaced by Pleasurecraft.

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 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 an authorized Pleasurecraft dealer as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

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

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INTRODUCTION - 1

PLEASURECRAFT MARINE ENGINE CO. GENERAL EMISSIONS WARRANTY

COVERAGE (Engines Manufactured after January 1, 2008 for CARB and after

January 1, 2011 for EPA)

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 inboard marine engine manufactured after January 1, 2008 for CARB and after January 1, 2011 for EPA, 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 three (3) years or 480 hours, whichever ﬁ rst occurs, 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 Environmental Protection Agency 40 CFR Part 1045 and Part 1068 and 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 Environmental Protection Agency and 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 three (3) years or 480 hours, whichever ﬁ rst occurs. 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 three (3) year or 480 hours, whichever ﬁ rst occurs, 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 three (3) years or 480 hours, whichever ﬁ rst occurs. 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 three (3) year or 480 hours, whichever ﬁ rst occurs, period.

5. Any part covered under this Warranty that is scheduled for replacement as required maintenance in the

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

6. Replacement of any part under this Warranty with a Pleasurecraft supplied part, will not shorten nor extend

the warranty period(s) stated in paragraphs one (1) thru four (4) above.

7. The engine owner will not be charged for diagnostic labor that is directly associated with diagnosis of

a defective, emission-related warranted part, provided that such diagnostic work is performed at a Pleasurecraft warranty station.

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L510010-11

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:

1. Fuel Metering System

A. Fuel Injectors B. Fuel Pressure Regulator C. Manifold Absolute Pressure Sensor D. Throttle Position Sensor E. Throttle Body - Port Fuel Injection Models F. Coolant Temperature Sensor G. Intake Valves H. Oxygen Sensors

2. Air Induction System

A. Intake Manifold B. Air Filter (Flame Arrestor)

3. Ignition System

A. Spark Plugs B. Electronic Ignition System C. Ignition Coil and/or Control Module D. Ignition Wires

4. Lubrication System A. Oil Pump and Internal Parts

5. Positive Crankcase Ventilation (PVC) System A. PCV Valve B. Oil Filler Cap

6. Exhaust System A. Exhaust Manifold(s) B. Exhaust Riser(s) C. Exhaust Valves D. Catalytic Converters

7. Miscellaneous Items Used on Above Systems A. Hoses, clamps, ﬁ ttings, tubing, sealing

gaskets or devices and mounting hardware B. Electronic Controls C. Electronic Control Module D. Pulleys, belts and idlers

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

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

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

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SAFETY INFORMATION

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

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

REPLACEMENT PARTS

DANGER

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

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

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

SAFETY WARNINGS

DANGER

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

WARNING

Indicates a potential hazard which could result in personal injury.

CAUTION

Indicates a hazard which could result in damage to equipment.

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

WARRANTY NOTICE: Indicates a possible warranty exclusion.

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BOATING RESPONSIBILITIES - 2

CARBON MONOXIDE HAZARD

DANGER

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

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

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

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

National Marine Manufacturers Association

200 East Randolph Drive

Suite 5100

Chicago, IL 60601-6528

www.nmma.org

312-946-6200

United States Coast Guard

Ofﬁ ce of Boating Safety

CG Headquarters G-OPB-3

2100 Second Street SW Washington, DC 20593

www.uscgboating.org

202-267-0984

American Boat & Yacht Council, Inc.

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

www.abyc.com

410-956-1050

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

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

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BOATING RESPONSIBILITIES - 2

SAFE BOATING SUGGESTIONS

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

• Power Squadrons

• Coast Guard Auxiliary

• Red Cross

• State, provincial or local agencies in charge of

water safety enforcement

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

WATER WISDOM

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

• Know your boat’s loading and operating

limitations. DO NOT OVERLOAD!

• Make periodic checks of safety equipment

onboard.

• Do not consume alcoholic beverages or take

illegal drugs when operating a boat. Some state laws apply to boats as well as motor vehicles.

• File a “ﬂ oat plan.” Let someone know your

destination and your expected time of return.

• Monitor the weather. Know the signs of weather

change and avoid severe weather and rough seas whenever possible.

• Follow the “Rules of the Road” when boating.

Always be on the alert and watch out for “the other guy.”

• Plan and chart your course. Be aware of, and

avoid, hazardous areas.

• Be sure your boat is equipped with the required

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

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

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

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

• Approved ﬁ re extinguishers.

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

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

• Spare propeller.

• Anchor and anchor line.

• First aid kit and ﬁ rst aid book.

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

• Manual bilge pump and spare drain plugs.

• Waterproof storage containers.

OPERATION AND MAINTENANCE

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

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BOATING RESPONSIBILITIES - 2

RULES OF THE ROAD

Channel Buoy Guide

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

2

2. Can Buoy: This buoy indicates the port

5

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)

12

Hurricane

Winds over

63 MPH

L510010-11

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.

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.

0,%!352%#2!&4-!2).%%.').%#/

-/$%, &)2).'/2$%2

3%2)!,

MFR DATE:

4()3%.').%#/.&/2-34/!,,!00,)#!",%53'/6%2.-%.4 34!.$!2$3!.$).4%2.!4)/.!,"/$%.3%%3()00).' #/--)33)/. 34!.$!2$#%24)&)#!4)/../-

&/2-!2).%%.').%3!44(%$!4%/&-!.5&!#452%

,)44,%-/5.4)!.3#

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. Multi-port Fuel Injection

Fuel Recommendations

Unleaded 87 Octane (minimum)

Engine Oil

15W-40 above 50 degrees F 5W-30 below 50 degrees F

Marine Gear Oil Recommendation

Dexron III

Electrical Specification

12 volts - Negative Ground

Ignition Timing and Engine Idle

Non-Adjustable (See CAM Retard)

Spark Plug P/N and Gap

R030010 - 0.060"

Maximum Engine Speed (WOT)

4800-5200 RPM (5000 RPM Preferred)

Maximum Continuous Cruise

4000 RPM

Firing Order

See Owner's Manual

CAM Retard

0-4 Degrees

Engine Coolant

TM

Long Life

Dex-Cool

Fuel Pressure - CHECK UNDER LOAD

57-62 psi @ W.O.T.

for your engine have not changed or been omitted.

Important! See your Owner's Manual to insure that the specifications

R143170B

1. ENGINE SPECIFICATION DECAL

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-/$%, &)2).'/2$%2

4()3%.').%#/.&/2-34/!,,!00,)#!",%53'/6%2.-%.4 34!.$!2$3!.$).4%2.!4)/.!,"/$%.3%%3()00).' #/--)33)/. 34!.$!2$#%24)&)#!4)/../-

&/2-!2).%%.').%3!44(%$!4%/&-!.5&!#452%

3%2)!,

,)44,%-/5.4)!.3#

MFR DATE:

2. ENGINE IDENTIFICATION DECAL

1

3

*Requires Special Diagnostic Tool

HIGHWAY 76 EAST

MARINE POWER

SERIAL N

OIL TYPE: DEXRON III

LITTLE MOUNTAIN S.C. 29075

o

PCM

MODEL

RATIO

CHECK OIL LEVEL DAILY OIL CHANGE AFTER FIRST 25 HOURS OF OPERATIONAND EVERY 100 HOURS OR 12 MONTHS, WHICHEVER OCCURS FIRST. IMPORTANT NOTE: WARRANTY IS VOID IF MAINTENANCEAND LUBRICATION INSTRUCTIONS PER PCM MANUALARE NOT FOLLOWED.

3. TRANSMISSION IDENTIFICATION PLATE

2

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:

L510010-11

13

ENGINE IDENTIFICATION - 3

ENGINE MODEL IDENTIFICATION / ADVISORY

MODEL 0 2 - 6 0 2 V - 0 1 SERIAL 515000

nd

1st - 2

Space: MANUFACTURING CODE

rd - 5th

3

Space: ENGINE CODE

502 = HO303 570 = EX343 602 = ZR409 603 = ZR450

th - 7th

Space: DRIVE CONFIGURATION

6 blank - Direct Drive V - V-Drive C - Catanium Clean Emissions System (CES)

PCM

*SERIAL NUMBER I.D.*

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

th - 9th

8

Space: SPECIFICATION CODE

14

L510010-11

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 pumps

• 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

• Throttle Control Position (TCP) Sensor

Additional Sensors for CES ENGINES

• Pre-Catalyst Oxygen (O2) Sensors

• Post-Catalyst Oxygen (O2) Sensors

• Exhaust Manifold Water Temp (EMWT) Sensors

If, for any reason, one or more of these sensors or associated wiring malfunctions, the ECM’s built-in selfdiagnostic system sets a trouble code and turns on the “MIL” Malfunction Indicator Lamp to alert the operator of a malfunction.

In most cases, when the “MIL” is on, the engine(s) may lose some performance and/or efﬁ ciency, but remain running adequately. Also, the light may go out or become intermittent, but a trouble code will be logged for future diagnosis. (See Engine Alarm System - page 16)

In any case, the operator must obtain service by an authorized PCM Premier dealer to determine the exact cause of the malfunction.

L510010-11

15

OPERATING INSTRUCTIONS - 5

ENGINE ALARM SYSTEM

The PCM engine electronic system is programmed to control the engine alarm system. This system utilizes an indicator lamp (“MIL” or “Check Engine”) and/or an optional audible alarm to warn the operator of possible engine problems.

The alarm circuit has a “self” checking feature programmed into the system. This feature will momentarily light the “MIL”, and if equipped, sound the alarm for two short pulses upon initial start-up of the engine.

If the “MIL” lights and/or the alarm sounds during operation, observe the instrument panel readings for the possible source of the malfunction, such as low oil pressure or excessive engine temperature readings.

Other conditions that may sound the warning buzzer are a transmission over-temperature warning (if equipped), exhaust gas over-temperature warning (if equipped), and for an electronic throttle malfunction.

ENGINE ALARM SYSTEM (CES ENGINES)

The PCM engine electronic system is programmed to control the engine alarm system. Your CES Engine Alarm System may utilize up to three (3) alarm circuits to warn you of a potential problem with your engine.

The Malfunction Indicator Lamp (MIL) is used for notiﬁ cation of any emissions-related fault. This is an amber indicator lamp, that may be labeled ‘Service Soon’ or with the ISO icon, to warn the operator of possible engine problems.

The alarm circuit has a “self” checking feature programmed into the system. This feature will light the “MIL” and “CGL” lamps, and also sound the buzzer for two short pulses upon initial start-up of the engine.

NOTE: If, during Key ON, engine OFF, either the MIL or CGL lamps are ﬂ ashing, this indicates that a stored trouble code or engine fault is recorded in the ECM. Refer to your dealer for proper diagnosis.

If the “MIL” or “CGL” lights and the alarm sounds during operation, observe the instrument panel readings for the possible source of the malfunction, such as low oil pressure or excessive engine temperature readings.

Other conditions that may sound the warning buzzer are a transmission over-temperature warning (if equipped), exhaust manifold water over-temperature warning , and for an electronic throttle malfunction.

IMPORTANT: A failure involving the Electronic Throttle may result in Idle only operation of the engine. The operator must obtain service by an authorized PCM Premier dealer to determine the exact cause of this malfunction as soon as possible.

In most cases, when the “MIL” or “CGL” lights are on, the engine may lose some performance and/or efﬁ ciency, but remain running adequately. Also, the lights may go out or become intermittent, but a trouble code will be logged for future diagnosis.

NOTE: If the MIL is blinking during Key ON, Engine OFF situation, that means there is a stored diagnostic trouble code.

In any case, the operator must obtain service by an authorized PCM Premier dealer to determine the exact cause of the malfunction.

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.

ISO Icon

The Check Gauges Lamp (CGL) is used for notiﬁ cation of any non-emissions-related fault. This is a red indicator lamp to warn the operator of possible engine problems such as low oil pressure or an over temperature condition.

The Buzzer is an audible notiﬁ cation to the operator, that may be used in conjuction with the MIL and/or CGL.

For events such as an engine over-temperature condition, low oil pressure, etc., the Buzzer will sound for 1/2 second ON, 1/4 second OFF, continuously as an audible warning. For emissions related faults (MIL), the buzzer will initially sound for 5 seconds, then will sound for 1/2 second ON once per minute thereafter. In the event of a MIL circuit failure, MIL circuit functions will be transferred to the Buzzer circuit.

16

L510010-11

INSTRUMENTATION

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

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

2. Water Temperature Gauge - indicates the engine coolant temperature

3. Oil Pressure Gauge - indicates the engine oil pressure

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

5. Hour Meter - indicates the engine operating time

6. Fuel Level Gauge - indicates the fuel tank level

7. Malfunction Indicator Lamp (MIL) or Check Gauges Lamp - indicates a problem with the engine control system

Notice: Many boat manufacturers are using Controller Area Network (CAN) based instrumentation. This instrumentation is driven by a two-wire network from the engine. Refer to your boat manufacturers Owners manual for the type of instrumentation being used with your application.

OPERATING INSTRUCTIONS - 5

40

0

80

OIL

170

100

200

TEMP

Figure 5-1 Typical Instrument Panel

MALFUNCTION INDICATOR LAMP

MIL

Figure 5-1A Typical Warning Lamp Cluster -

STARTING ENGINE (FUEL INJECTED ENGINES)

CHECK

ENGINE

20

10

0

30

40

60

TAC H

CES Engines

10

50

E

CHECK GAUGES LAMP

CGL

13

16

VOLT

1/2

F

FUEL

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/Operation manual for speciﬁ c operation and troubleshooting information for your speed control system.

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

• Exhaust system for leaks and tightness of the clamps

L510010-11

17

OPERATING INSTRUCTIONS - 5

• 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-

2). 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. 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.

5. Do not pump or open the throttle when starting the engine (Figure 5-3). The ECM will automatically regulate the fuel and control desired idle speed.

PCM has introduced a product enhancement feature on all PCM Mulitport Fuel Injection Products. Your engine may be equipped with the engine auto-crank feature. This feature allows the engine to automatically crank, or turn over, when commanded. Once the operator has turned the key to the START position on a key switch, or depressed the START button on a touchpad, the engine will automatically turn over and start. The engine will turn over until the engine starts, or a maximum of 5 seconds. The key switch or stop button can always be utilized in order to cease the engine from cranking and/or starting.

Important: In the event that the engine must be turned over WITHOUT automatically cranking or starting (i.e. bumping the engine to #1 position or performing a compression check) a remote starter button MUST be used, connected directly to the starter solenoid and the ignition system disabled.

Check for signs of external leaks

Figure 5-2 Water Leaks

Check for signs of external leaks

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.

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, ensure the Neutral Lockout is engaged and move the throttle lever to a 100% open position (Figure 5-3). 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.

NOTICE: Single lever throttle/shift handles use different mechanisms to achieve Neutral Lockout or throttle only operation. Some require you to push in on a button while moving the handle forward, others require the button to be pulled out. Refer to your boat owners manual for complete instructions on throttle/shift lever operation.

18

L510010-11

OPERATING INSTRUCTIONS - 5

FORWARD THROTTLE RANGE

NEUTRAL LOCKOUT

FORWARD SHIFT RANGE

IDLE

NEUTRAL

REVERSE SHIFT RANGE

IDLE

REVERSE THROTTLE RANGE

SAFETY COLLAR

FULL THROTTLE

Figure 5-3 Typical Throttle / Shift Position Settings

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.

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.

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.

FULL THROTTLE

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.

2. Pull up on the Safety Collar and slowly push the throttle/shift handle into the Forward gear Idle position.

Throttle may be increased/decreased as required in the Forward Throttle Range.

3. Pull up on the Safety Collar and slowly pull the throttle/shift handle back into the Reverse gear Idle position.

Throttle may be increased/decreased as required in the Reverse Throttle Range.

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

L510010-11

19

OPERATING INSTRUCTIONS - 5

STOPPING ENGINE

When returning to the dock, or whenever stopping the engine, bring the throttle back to the idle position and the transmission to Neutral. 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.

20

L510010-11

PCM BASIC CRUISE SPEED CONTROL SYSTEM (OPTIONAL)

Cruise Mode allows electronic control of the engine at an operator selected boat or engine speed. The operator has the option of entering Cruise Mode one of two ways. MPH Mode allows the operator to set a cruise speed based on boat speed. RPM Mode allows the operator to set a cruise speed based on engine RPM. When you are in Cruise Mode, the engine is electronically controlled to maintain the desired MPH selected, or engine RPM, regardless of sea conditions or maneuvers.

NOTE: Your application may consist of a Digital Speed Control operated by a Controller Area Network (CAN) device. Refer to your boat dealer for clariﬁ cation of the system on your application.

MPH CRUISE MODE

When the Basic Cruise System is operated in the MPH Mode, the operator will select the desired boat speed he wishes to maintain. Boat speed information is provided to the ECM via the paddle wheel. The paddle wheel is the same device that provides speed information to the boat’s speedometer. As load conditions change on the boat, such as a skier or wake boarder pulling against the boat or the boat entering / exiting a turn, the speed of the boat typically will vary; however, the ECM monitors these variations based on the paddle wheel input and responds by increasing or decreasing engine RPM to maintain the operator selected boat speed.

IMPORTANT: If the paddle wheel input is lost, while operating in the MPH Cruise Mode, engine RPM will increase by approximately 60 rpm. The operator will feel this as a ‘bump’ as boat speed increases and the MIL or Check Engine Lamp will be lit. Speed will remain constant at this new point. If the paddle wheel input is re-established, boat speed will drop to the operator set point and the MIL will turn OFF.

If you enter MPH Cruise Mode and there is no input from the paddle wheel, when you set a new speed or resume the previous set speed, the system will initially hold the set speed then slowly begin to ramp the speed up to throttle handle position and turn on the MIL. Pull the throttle handle back and exit MPH Cruise Mode. RPM Cruise Mode is not affected by the loss of the paddle wheel input.

With the engine off and the boat on a lift or the trailer, inspect the paddle wheel for damage or blockage. If you are unable to correct the problem at the paddle wheel, contact your authorized PCM Premier Dealer for service.

RPM CRUISE MODE

When the Basic Cruise System is operated in the RPM Mode, the operator will select the desired engine RPM he wishes to maintain. Engine speed or RPM

OPERATING INSTRUCTIONS - 5

esiurC

HPM seR/)+(

esiurC

MPR

Figure 5-4 PCM Basic Cruise Control Panel (Typical)

information is monitored by the ECM, and is the same signal information the ECM provides to drive the Tachometer on the instrument panel. The ECM monitors the tach signal and maintains engine RPM at the operator selected point. As load conditions change on the boat, such as a skier or wake boarder pulling against the boat or the boat entering / exiting a turn, the speed of the boat typically will vary; however, engine RPM should remain at the operator selected point.

ENTERING CRUISE MODE

1. Select the desired cruise mode by pressing the MPH/RPM Cruise switch to the MPH or RPM position.

NOTE: The Cruise Lamp should be OFF. If the Cruise lamp is blinking, the system has “remembered” a set speed from a previous Cruise Mode operation. If this speed is unknown, or is not the desired set speed, simply press the Speed Cancel switch and the lamp will turn OFF.

2. Move the throttle to the desired speed.

3. Press the Speed Set switch. The Cruise Lamp will blink until the throttle handle is moved above the set point. Push the throttle handle to the full forward position.

NOTE: The throttle handle should be in the full forward position at this time. This allows the electronic control sufﬁ cient range to adjust and maintain the engine at the desired set speed.

4. The Cruise Lamp should be steady ON indicating that Cruise Mode is engaged.

5. Pressing the Speed (+)/Res (Increase/Resume) or (-) (decrease) switch allows the operator to adjust the set speed up or down 20 RPM, or.25 MPH, each time the switch is engaged.

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L510010-11

21

OPERATING INSTRUCTIONS - 5

NOTE: Depressing and holding the Speed (+)/(-) switch

for 3 seconds or longer will cause the speed to slowly ramp up ((+)/Res) or down (-). Release the switch when the desired speed is achieved, this will be the new set speed.

CANCELLING THE CRUISE SET-POINT

1. Press the Speed Cancel switch.

2. Pull the throttle handle back below the set point.

3. The Cruise Lamp will go OFF indicating that the operator has full throttle control over the engine.

IMPORTANT: The ECM ‘remembers’ the previous set point of a Cruise Mode operation. This means that you may have two set points in memory, one for MPH Mode and one for RPM Mode. ONLY the Cruise speed set-point for the current cruise mode (MPH or RPM) has been cancelled. At this point, a new set speed could be selected, you may use the Resume Mode to go back to the previous set speed, or you could change cruise mode and use Resume or Set Speed in the newly selected cruise mode.

RESUME MODE

1. After cancelling a Cruise Mode set speed, the previous set speed can be resumed by pressing the Speed (+)/Res switch, then pushing the throttle handle forward above the previous Cruise set-point.

NOTE: The operator may disengage Cruise Mode at any time by pulling the throttle handle back below the set point. The Cruise lamp will ﬂ ash indicating that Cruise Mode is still requested, but not engaged. If the throttle handle is pushed forward past the previous set-point, while the Cruise lamp is blinking, Cruise will Resume at the previous set-point, and the Cruise lamp will be steady ON.

EXITING CRUISE MODE

1. Press the MPH/RPM switch to OFF.

2. The Cruise Lamp will go OFF. Cruise mode will remain engaged until the operator pulls the throttle handle back below the set point.

esiurC

HPM seR/)+(

esiurC

MPR

Figure 5-4 PCM Basic Cruise Control Panel (Typical)

Lamp will be off. If the operator simply pulled the throttle back to neutral and shut off the engine while cruise mode was engaged, the Cruise Lamp will be blinking and as the throttle handle is pushed forward past the previous set point, cruise would resume.

If the Cruise lamp is ﬂ ashing when you re-start the engine, simply press the Speed Cancel switch, or turn the Cruise Mode switch OFF, to regain full throttle control .

The ECM remembers the last programmed Cruise speed, even if the Speed Cancel switch has been pressed. If you wish to resume Cruise Mode at the previously selected speed, select the desired cruise mode (MPH or RPM, if the switch is in the OFF position), then press the Speed (+)/Res switch, the Cruise Lamp will begin ﬂ ashing and Cruise will be engaged when the throttle handle passes the previous set-point. Or, you may set a new Cruise speed by pressing the Speed Set switch at the new desired engine speed.

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IMPORTANT: It is good practice to always exit

Cruise Mode properly, prior to shutting off the engine. If the engine is turned off while the Cruise

Mode switch is in MPH or RPM Mode, the ECM is still being commanded to be in the Cruise mode. The ECM remembers the last set speed for each cruise mode and the last switch command prior to being shut off. When the engine is re-started, Cruise Mode will be resumed. If Speed Cancel was the last operation prior to turning the engine off, the Cruise

22

L510010-11

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).

L510010-11

23

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 the pitch of a given propeller will generally change engine RPM by 150 to 250 RPM.

ENGINE RPM CHART

Minimum Model Full Load Preferred Maximum

HO303 4800 4900 5000

EX343 5000 5200 5300

ZR409/ZR450 5400 5500 5600

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 prolonged WOT operation are considered abuse and are not covered under the PCM Warranty.

IMPORTANT NOTICE: Your new PCM engine

incorporates an RPM “MAX GOVERNOR” in order to prevent the engine from over-revving. Operation above the Maximum RPM listed, in the chart above, is not recommended. If your engine is operating above the maximum RPM listed, a higher pitched propeller would be required to lower the engine maximum RPM to the Preferred RPM listed in the chart above.

24

L510010-11

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.

L510010-11

25

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 Premier 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 pre-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.

26

L510010-11

FUEL REQUIREMENTS - 9

GASOLINE REQUIREMENTS

CAUTION

Fire and Explosion Hazard - Gasoline is extremely

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

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

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

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

$

UNLEADED

REGULAR

87

E10

MINIMUM OCTANE RATING

R + M/2 METHOD

87

E10

Figure 9-1 Fuel Requirements

NOTICE: PCM Fuel Injected engines are calibrated to operate on and provide optimum performance when using fuel with at least an 87 octane fuel rating. PCM’s engine control module incorporates Adaptive Learn Technology to ensure optimum engine performance is obtained when using fuel rated higer than 87 octane.

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 Marine Engines Premier service technician.

ATTENTION: For optimal performance and reliability, the ZR450 application requires the use of premium 93 Octane fuel.

GASOLINE CONTAINING ALCOHOL

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

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

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

CAUTION

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

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

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

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

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

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

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

Fuel Stabilizer Recommendations for Ethanol Blend Fuel

The use of a commercially available fuel stabilizer, such as STA-BIL®, is recommended at each ﬁ ll-up or when storing ethanol-blended fuel for more than 2 weeks.

L510010-11

27

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 may be used in PCM Marine Engines. Synthetic oils must meet the Engine Oil Requirements for Classiﬁ cation and Viscosity listed below. The use of synthetic oil 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 “GF-4/SM”

Below 50˚F SAE 5W-30 “GF-4/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 (R190250)

Walters “V”-Drive SAE 30

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

28

L510010-11

ENGINE MAINTENANCE

Refer to the MAINTENANCE SCHEDULE for a complete listing of required maintenance and the frequency at which it should be performed. While some procedures may be performed by the owner/operator, PCM Engines strongly recommends that all engine service and maintenance be performed by an authorized PCM Engines Premier 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. Excessive oil can lead to premature engine component failure and/or loss of performance.

IMPORTANT: The engine oil level must be checked

while the boat is in its normal, level, at rest position on the water. Excessive wave action side to side or fore and aft may cause you to obtain erroneous readings. If the oil level is being checked while the boat is on a trailer, ensure the trailer is on level ground, then adjust the trailer so the boat is at its normal, at rest position. Excess water in the bilge and, if equipped, ballast systems must be purged when checking the engine oil level, otherwise erroneous readings may be obtained.

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 until it is within two (2”) inches of being fully seated. Slowly move the dipstick up and down approximately one-half (1/2”) several times; then fully seat the dipstick into the dipstick tube.

3. In order to obtain an accurate reading, wait two minutes for the oil to stabilize on the dipstick. 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. If the oil level is above the “FULL” mark on the dipstick, remove the excess oil. (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.

L510010-11

29

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 11-3 Transmission Dipstick and Location

Figure 11-2 Transmission Dipstick and Location

30

L510010-11

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 ‘Maintenance 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. PCM P/N: R190250.

1. Remove the drain/ﬁ ll/dipstick plug from the transmission. Wipe the dipstick clean and insert into transmission - Do Not Screw the dipstick into the hole. Remove and observe the ﬂ uid level.

2. The ﬂ uid level should be between the FULL mark and the end of the dipstick. If a plug is

used, ﬂ uid level should be to 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/dipstick plug(s) and tighten securely.

LUBRICATION

Throttle Cable

Lubricate pivot points and exposed cable (Figure 11-5) with SAE 30W-30 engine oil.

BALL JOINT

CABLE

CLIP

LUBRICATION

POINTS

Figure 11-5 Typical Throttle Cable

Shift Cable

Lubricate pivot points and exposed cable (Figure 11-6) with SAE 30W-30 engine oil.

R041091

Oil Fill/Drain

Plug

PLEASURECRAFT

ENGINE GROUP

POWER PLUS

1.48

O

RATI

MADE IN USA

Raw Water Drain Plug

Figure 11-4 Transmission Service Location

OR

FULL

LOW

Oil Fill/Drain

Plug

LUBRICATION

POINTS

Figure 11-6 Typical Shift Cable

L510010-11

31

ENGINE MAINTENANCE - 11

ELECTRICAL SYSTEM RELAY AND FUSE BLOCK

MAIN PANEL FUSE

PCM engines are equipped with a 40 Amp PANEL fuse which provides electrical overload protection for the boat’s instrumentation wiring and components. Should an electrical overload occur, the PANEL fuse will open and prevent electrical current ﬂ ow.

When this fuse opens, the cause for the high current draw must be found and corrected. Check the battery and alternator connections and all other harness connectors between the boat and the engine main harness. Check for loose or disconnected lead wires and shorted circuits. Replace the PANEL fuse and resume operation. If the cause of the overload cannot be found, consult an authorized PCM Engines dealer to make necessary repairs.

ELECTRICAL SYSTEM FUSES

PCM engines utilize fuses to protect critical engine components and devices. The fuel pump, ECM, ignition components, fuel injectors, starter and diagnostic devices are protected by fuses. The fuse block is mounted on a bracket near the rear of the engine.

20

40

20 20

20

5

20

15

BOAT’S 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 the neutral position and the safety lanyard (if equipped) is attached properly. If none of the Fuse Block fuses are open, check for a blown boat ignition fuse. The boat’s ignition fuse may be located on the instrument panel, the fuse holder block or as part of the helm’s instrument wiring harness. Check the wiring diagrams supplied from the boat manufacturer for the exact location.

ELECTRICAL SYSTEM WIRING AND CONNECTORS

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

Figure 11-7 (Typical) Electrical System Relay and Fuse

Block

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.

32

L510010-11

WARNING

ENGINE MAINTENANCE - 11

FRESH-WATER COOLING SYSTEM SACRIFICIAL ZINC ANODE

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.

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

• 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.

Figure 11-8 Zinc Anode Location F.W.C. Heat

Exchanger (6.0L)

L510010-11

33

ENGINE MAINTENANCE - 11

CHECKING COOLANT LEVEL

WARNING

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

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.

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.

PRESSURE

DEGAS

BOTTLE

Figure 11-9 Checking Coolant Level (6.0L)

CAP

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.

ATTACH FLUSHING ADAPTER

HERE

Figure 11-10 Typical Sea-Water Inlet

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 standard ethylene glycol coolant in the system every two years or long life coolant, Dex-Cool™, every ﬁ ve years to prevent a build-up of harmful chemicals within the fresh-water system.

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.

34

L510010-11

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

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.

DRAINING FRESH-WATER PORTION OF THE COOLING SYSTEM

NOTICE: To protect the environment, dispose of

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

NOTICE: In order to drain the raw-water portion of the systems, refer to WATER FLOW DIAGRAMS section of this manual for proper locations.

Remove the following drain plugs/hoses in order to drain the coolant from the fresh-water portion of the cooling system.

HO303 / EX343 Half-System

A. Fresh-Water drain plug from heat exchanger. B. Drain plug from coolant pipe as shown in Figure

11-11.

C. Drain plugs from each side of the cylinder block,

these will be the knock sensors.

Remove DRAIN PLUG

(as equipped)

Figure 11-11 Draining Engine Circulating Pump

(5.0/5.7L)

ZR409 / ZR450 Half-System

A. Fresh-Water drain plug from heat exchanger. B. Remove large hose from the engine block water

circulating pump.

C. Drain plugs from each side of the cylinder block.

ZR409 CES / ZR450 CES Full-System

A. Fresh-Water drain plug from heat exchanger. B. Remove large hose from the engine block water

circulating pump. C. Drain plugs from each side of the cylinder block. D. Remove the hose and/or drain plug from the

bottom of each exhaust manifold. E. Remove the drain plug from each exhaust

corner.

ZR450 CES Half-System

A. Fresh-Water drain plug from heat exchanger. B. Remove large hose from the engine block water

circulating pump. C. Drain plugs from each side of the cylinder block.

NOTE: After the system has drained completely, coat drain plugs with PerfectSeal (or equivalent) and reinstall in proper locations. Reinstall hose(s) and tighten clamps securely as required.

L510010-11

35

ENGINE MAINTENANCE - 11

FILLING FRESH-WATER COOLING SYSTEM (Non-Catalyst and Half-System Applications)

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

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

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

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

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

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

DEX-COOL™ can become contaminated by inadvertently topping-off with conventional coolant, adding conventional coolant to the system or even if ﬁ ll/drain containers are shared between coolants. If contamination occurs, the cooling system must be immediately drained and ﬂ ushed, and reﬁ lled with DEX- COOL™. 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.

3. Start the engine and operate at idle speed (12001500 RPM) to purge any air from the system. When the system is full, install the pressure cap.

ANTIFREEZE

SOLUTION

Figure 11-12 Filling F.W.C. System (6.0L)

36

L510010-11

1. If the system contains a heater, close both ball valves. Disconnect both hoses from the ball valves and plug hoses to prevent leakage.

ENGINE MAINTENANCE - 11

FILLING FRESH-WATER COOLING SYSTEM

(ZR409 CES / ZR450 CES Full-Fresh Applications)

2. First, raise the degas bottle from the lower, or running location, to the upper, or ﬁ lling location, of the bracket.

If the bottle can be held higher

than that, ﬁ lling goes quicker.

Lower Location

Upper Location

L510010-11

37

ENGINE MAINTENANCE - 11

3. Remove the cap from the degas bottle. Open the heat exchanger bleed valve and keep ﬁ lling until solid liquid is achieved from the drain hose.

Note: Make sure the drain hose is uncoiled and ﬂ owing freely.

Note: A plug may have to be removed from the end of the drain hose.

4. Add 50/50 mixture of Dexcool, or equivalent, to the degas bottle.Keep adding to the bottle until solid liquid comes out the drain hose, making sure all air is purged.

Note: Keeping the bottle ﬁ lled to the top, or raising the bottle above the bracket, will accelerate the ﬁ lling process.

5. Once solid liquid is achieved, close the bleed valve.

6. Open up the heater ball valve near the thermostat housing.

Note: A plug may have to be removed if no heater hose was previously connected here.

7. Once solid liquid is achieved, close the ball valve.

Heater Ball

Valve

Heat Exchanger Bleed Valve

(uncoil hose prior to bleeding)

8. Using a 7/32” allen head, remove the port side exhaust manifold bleeder plug. Keep adding to the bottle until solid liquid comes out the top of the manifold, making sure all air is purged.

9. Once solid liquid is achieved, install and tighten bleeder plug.

10. Repeat steps 7 and 8 for starboard manifold.

Port Side

Manifold

Bleeder

Starboard

Side Manifold

Bleeder

38

L510010-11

11. Return the degass bottle to the lower, or running position. Make sure the bottle level is at the “Min” mark on the bottle and tighten the cap.

ENGINE MAINTENANCE - 11

Upper Location

Lower Location

Important: If a heater is used, the complete heater system, hoses and core, should be preﬁ lled by either pumping or

sucking Dexcool through the system. Once the heater system is preﬁ lled, the hoses can be attached to the ball valves and the ball valves need to be opened.

Once the system has heated up and cooled down, it is not uncommon to have to add a little bit of coolant after the ﬁ rst couple of heat cycles.

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

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

be boiled out (such as a radiator repair facility).

HEAT

EXCHANGER

PLATE

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.

L510010-11

COOLANT

DRAIN PLUG

RAW WATER

DRAIN PLUG

GASKET

BOLT

Figure 11-13 Heat Exchanger and End Plate Removal

(Typical)

39

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

Accumulation of water and other fuel contaminants may form corrosive compounds that can damage the fuel ﬁ lter, and result in fuel leakage. Ethanol blended fuel may increase this risk. For this reason, annual replacement of the fuel ﬁ lter, at a minimum, is required to avoid risk of explosion or ﬁ re.

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.

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.

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.

40

L510010-11

FUEL

CONTROL

CELL

LOW-PRESSURE

FUEL PUMP

FUEL

SUPPLY

LINE

FUEL

RETURN

LINE

5.0/5.7L ONLY

ENGINE MAINTENANCE - 11

RETURN

TO

FUEL

TANK

FROM

FUEL

TANK

Figure 11-14 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.

Fuel/ WaterSeparating Filter

ElementPart NumberR077019 ManufactureDate 10/03/09

TestedToISO, SAE,and JICStandards at 5PSI

WARNING-PRESSURIZEDGASOLINE FUELSYSTEM-FIRE HAZARD

ToReplace FilterElement: Slowlyturn elementcounter clockwiseto relieve fuelsystem pressure. Oncesystem pressureis relievedremove filter elementtaking carenot tospill fuel. Lubricatethe O-ringof thenew filter witha smallamount oflubricating oil. Installfilter turningit clockwiseuntil hand tightplus 2/3to 1turn.

PRIMARY

FUEL

PRE-FILTER

NOTE: Some earlier models

may have an inline filter as shown below.

INOUT

PN: R080024A

FCC Fuel Filter (FCC Clamp-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 connectors from the FCC and the Low Pressure Fuel Pump (LPFP).

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.

L510010-11

41

ENGINE MAINTENANCE - 11

Draining the FCC Bowl, ENGINE OFF

1. Disconnect the two-wire electrical connectors from the FCC and the Low Pressure Fuel Pump (LPFP).

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 connectors to the FCC and LPFP.

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.

WARNING

6.0L 5.0/5.7L

RETAINING

CLAMP

OR

O-RINGS

FUEL

PRESSURE

REGULATOR

FUEL PUMP

FUEL

FILTER

Residual fuel will leak from the pump and the supply line. Elevate and plug the supply line to minimize fuel leakage. Capture/clean-up spilled fuel as required. Dispose of shop towels in an approved container.

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 connectors from the FCC and the Low Pressure Fuel Pump (LPFP).

2. Disconnect the fuel supply line from the LPFP.

3. 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.

4 Remove the canister retaining clamp.

5 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.

6. 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.

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

FUEL

BOWL

FUEL

DRAIN

Figure 11-15 Fuel Control Cell (FCC) - Clamp-on

Canister (Typical)

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

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

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

CAUTION: Use only fuel approved O-rings (R047241) provided in RP080026 Kit. Use of nonapproved O-rings may cause fuel to leak from the FCC.

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

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

12. Install and tighten the 7/16” plug into the canister.

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

14. Reinstall the retaining clamp and tighten securely.

42

L510010-11

ENGINE MAINTENANCE - 11

15. Reconnect the fuel supply line to the LPFP.

16. Reconnect the two-wire electrical connectors to the FCC and the LPFP.

17. 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.

18. 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.

Servicing the Primary 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 after the ﬁ rst 25 hours, then every 50 hours or once a year (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 or element replacement.

Filter Element Replacement, ENGINE OFF

PRIMARY FUEL PRE-FILTER #: R077019 (SPIN-

ON)

NOTE: This ﬁ lter may be located in various locations.

Consult your boat manufacturer’s operation manual for correct location.

1. Loosen the fuel ﬁ lter by spinning it counterclockwise. A ﬁ lter wrench may be required.

2. Remove the ﬁ lter. Ensure that the old O-ring is removed with the ﬁ lter.

3. Install the new ﬁ lter by spinning it on clockwise.. Ensure the new ﬁ lter is installed correctly. Tighten the ﬁ lter securely.

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

Fuel / Water Separating Filter

Element Part Number R077019 Manufacture Date 10/03/09

TestedTo ISO, SAE, and JIC Standards at 5 PSI

WARNING-PRESSURIZEDGASOLINE FUELSYSTEM-FIRE HAZARD

ToReplace Filter Element: Slowly turn element counter clockwise to relieve fuel system pressure. Once system pressure is relieved remove filter element taking care not to spill fuel. Lubricate the O-ring of the new filter with a small amount of lubricating oil. Install filter turning it clockwise until hand tight plus 2/3 to 1 turn.

P/N R143213

PRIMARY FUEL PRE-FILTER #: R080024A

(INLINE)

NOTE: This ﬁ lter may be located in various locations.

Consult your boat manufacturer’s operation manual for correct location.

1. Disconnect the fuel lines from the input and output of the ﬁ lter and block the lines to prevent fuel spillage.

2. Remove the ﬁ lter.

3. Install the new ﬁ lter. Ensure the new ﬁ lter is installed correctly. Input side of the ﬁ lter is from the fuel tank and output is to the engine.

4. Re-install the fuel lines and tighten the retaining clamps securely.

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

INOUT

PN: R080024A

R077019

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.

WARNING

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

L510010-11

43

ENGINE MAINTENANCE - 11

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 securing the ﬂ ame arrestor to the air intake 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 securely.

FLAME

ARRESTOR

THROTTLE

BODY

ACCESSORY DRIVE BELT

PCM engines use 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

Figure 11-16 Flame Arrestor - 5.7L (Typical)

DRIVE BELT REPLACEMENT

5.0/5.7L (LH) SERPENTINE BELT #: R066028

6.0L SERPENTINE BELT #: R066033

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.

44

L510010-11

ENGINE MAINTENANCE - 11

Alternator

Belt

Tensioner

Idler

Circulation

Pump

Crankshaft

Pulley

Raw Water

Pump

A

Figure 11-17 6.0L Accessory Drive Belt Conﬁ guration

Belt

Tensioner

A

Circulation

Pump

Crankshaft

Pulley

Raw Water

Pump

Figure 11-19 5.0/5.7L Accessory Drive Belt

Conﬁ guration

Alternator

Figure 11-18 Belt Tensioner (6.0L)

Figure 11-20 Belt Tensioner (5.0/5.7L)

SERVICING RAW WATER PUMP IMPELLER

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” (Figures 11-17 / 11-19) 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.

L510010-11

45

ENGINE MAINTENANCE - 11

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.

The transmission oil change should be performed by an authorized PCM Premier 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.

OIL QUICK-DRAIN

HOSE

CONTAINER

Figure 11-21 Engine Oil Removal

OIL

FILL

CAUTION

DO NOT OVERFILL ENGINE CRANKCASE WITH OIL. Excessive oil can lead to premature engine component failure and/or loss of performance.

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 11-21). 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.

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.

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 and quantity, through the oil ﬁ ll location on the valve

Figure 11-22 Engine Oil Fill (5.7L)

cover (Figure 11-22). See OIL REQUIREMENTS page 28 and ENGINE FLUID CAPACITIES page 54, respectively.

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. Add or remove oil, as needed, to bring the engine oil to the proper level. See CHECKING FLUID LEVELS page 29 for Important Notes and Cautions to observe when checking the engine crankcase oil level.

IF YOU ARE UNSURE OF THE CORRECT AMOUNT OF OIL TO USE DURING A SERVICE INTERVAL, PERFORM THE FOLLOWING PROCEDURE:

(1) Drain the oil and change the oil ﬁ lter.

46

L510010-11

ENGINE MAINTENANCE - 11

(2) Add four (4) quarts of new oil.

(3) Start and run the engine allowing sufﬁ cient time for

the new oil to circulate and ﬁ ll the new oil ﬁ lter.

(4) Shut the engine off. Wait 5 minutes to allow the oil

to completely drain back to the pan. Check the oil level with the dipstick and add the correct amount of oil to ﬁ ll to the “FULL” mark on the oil level dipstick.

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 V-Drive applications, adjust the engine and V-Drive mounts to achieve alignment. The Transmission mounts are for support only and, are not used to achieve proper alignment.

The Transmission mounts may need to be adjusted so there is no tension on the mounting bolts as they are re-installed. Re-tighten all trunnion bolts to complete the V-Drive alignment.

NOTE: Some PCM V-Drive conﬁ gurations use only engine and transmission mounts. Alignment is accomplished using those mounts.

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 11-24).

PLEASURECRAFT

ENGINE GROUP

POWER PLUS

1.48

TIO

RA

MADE IN USA

Figure 11-23 PCM V-Drive

V-DRIVE ALIGNMENT

The Transmission support mounts must be removed before performing the engine alignment. Alignment is achieved using the Engine front mounts and the PCM V-Drive rear mounts.

• Alignment with a PCM V-Drive: loosen the trunnion bolts on the TRANSMISSION mounts, then remove the bolts used to attach the mount to the Transmission. Slide the mount away from the transmission.

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 Transmission.

Figure 11-24 Shaft Mating Surface Check

2. Center the propeller shaft in the shaft log as follows: (Figure 11-25)

• 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.

L510010-11

47

ENGINE MAINTENANCE - 11

.003 INCH (0.07 mm)

FEELER GAUGE

TRANSMISSION

OUTPUT FLANGE

A

B

A

Figure 11-25 Centering Prop Shaft

3. Check that the coupling center lines align by butting the propeller shaft coupling against the transmission coupling (Figure 11-26). 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 11-27 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 11-26 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 11-27).

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

LOCKING

NUT

ADJUSTING

NUT

Figure 11-28 Mount Adjustment

48

L510010-11

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 11-29 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 11-31 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 11-31).

TRANSMISSION

OUTPUT FLANGE

STRAIGHT

EDGE

A

LC

RC

1.750 in. MAX (44.45 mm)

TRUNNION

BOLT

Figure 11-30 Engine Extension

B

LC

B

RC

A

Figure 11-32 Angular Alignment Check

IMPORTANT: Angular misalignment conditions may require adjustment of one front mount, both front mounts, the trunnions, or any combination. Figure 11-32 (Angular Alignment Check) and the following table are to assist in the alignment process.

L510010-11

49

ENGINE MAINTENANCE - 11

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 11-32), 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.

• 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)

50

L510010-11

ENGINE MAINTENANCE - 11

ENGINE MAINTENANCE LOG

Operating Date Maintenance/Repair Hours

L510010-11

51

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

1

X

1

X

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

52

L510010-11

2

X

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

1

X

MAINTENANCE SCHEDULE (cont’d)

Fresh-water cooled models - Clean sea-water section As required 3 (X)

Fresh-water cooled models - Check coolant for alkalinity At least once each year (X)

Fresh-water cooled models - Change coolant Every ﬁ ve years

Zinc Anodes - Heat exchanger and cooler - check condition Every 30 days 3 (X)

Engine Assembly Exterior Surfaces - spray with rust- Fresh water areas - Every 60 days (X) preventative oil (D) Salt water areas - Every 30 days (X)

Cooling System (SALT WATER AREAS ONLY) - Flush sea-water section After use each day (X)

Notes:

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

operator

(O) Denotes service to be performed by an authorized

PCM Engines Premier dealer

(A) Use SAE 30 engine oil

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

Dexron III automatic transmission ﬂ uid

(C) All PCM Power-Plus “V” Drive transmissions are

designed to be ‘Maintenance 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. PCM P/N: R190250

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

L510010-11

(D) Use WD-40 penetration oil or equivalent

1

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).

2

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).

3

Requires more frequent inspection if used in extremely

salty, polluted or mineral-laden waters.

4

See COOLANT SPECIFICATIONS.

PCM Engines recommends that all periodical and annual service be performed by your local, authorized PCM Engines Premier dealer.

53

ENGINE MAINTENANCE - 11

VISUAL INSPECTION

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

It is important for the owner/operator to visually inspect

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

Protect engine ﬁ nish from corrosion by periodically

spraying the engine exterior ﬁ nish with a rust

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

ENGINE FLUID CAPACITIES

Model ALL MODELS

Crankcase Oil Capacity W / NEW FILTER Start with 4 Quarts (4.5 L)

1

Fresh Water Cooling System Capacity Fill Until Completely Purged

3

TRANSMISSION FLUID CAPACITIES

Model All Models Type

PCM, 1:1 Ratio

PCM, 1.23:1 Ratio

1,2

2.0 Quarts (1.9 L) DEXRON III

1,2

2.0 Quarts (1.9 L) DEXRON III

Hurth (Exc. V-Drive), All Ratios

Hurth V-Drive, All Ratios

1,2

4.0 Quarts (3.79 L) DEXRON III

1,2

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

Mobiltrans SHC 50 PCM Power-Plus V-Drive, All Ratios

1,2

1.5 Quarts (1.42 L) synthetic - R190250

Walters RV-36D V-Drive 1.5 Quarts (1.42 L) SAE 30 1 - Engine Fluid Capacities are dependent on installation angle. DO NOT overﬁ ll the crankcase or

transmission. Remove excess ﬂ uid above the “FULL” mark on the dipstick. Check oil with the boat at its normal, level, at rest position on the water. Ensure that ballast systems (if equipped) and excess water in the bilge have been purged. If the boat is on a trailer, the trailer must be level and adjusted to represent the boat’s normal resting state on the water. Oil capacities are approximate, and may not include capacity needed for transmission cooler and oil lines. Refer to the Checking Fluid Levels instructions page 29 and Changing Oils instructions page 46, of this manual, for complete instructions, important notes and Cautions for checking engine oil levels. 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 - Refer to the Checking Fluid Levels instructions pages 30-31 of this manual for complete instructions for

checking transmission ﬂ uid levels. IMPORTANT: Fluid levels on the PCM 1:1 and 1.23:1 transmissions are checked while the engine is running. All other transmission ﬂ uid levels are checked at operating temperature and immediately after shutdown of the engine.

3 - Fresh Water Cooling systems vary depending on half-systems, full-fresh systems, heaters, hose lengths,

etc. System should be completely purged of air and the coolant level should be within the MIN/MAX level of the degas bottle after the engine has been ran at operating temperature and the system is allowed t to cool down overnight. Top off as necessary. Refer to FILLING FRESH-WATER COOLING within this section.

54

L510010-11

ENGINE MAINTENANCE - 11

FILTER REQUIREMENTS

Description Part No.

Oil Filter (remote-mounted) R077001

Kit, Transmission Oil Filter (ZF) RP077011

Primary Fuel Pre-Filter R077019

Primary Fuel Pre-Filter R080024A

Fuel Control Cell (FCC) Fuel Filter Element RP080026

PN: R080024A

RP080026

INOUT

Fuel / Water Separating Filter

Element Part Number R077019 Manufacture Date 10/03/09

TestedTo ISO, SAE, and JIC Standards at 5 PSI

WARNING-PRESSURIZEDGASOLINE FUELSYSTEM-FIRE HAZARD

ToReplace Filter Element: Slowly turn element counter clockwise to relieve fuel system pressure. Once system pressure is relieved remove filter element taking care not to spill fuel. Lubricate the O-ring of the new filter with a small amount of lubricating oil. Install filter turning it clockwise until hand tight plus 2/3 to 1 turn.

P/N R143213

R077019

PCM POWER-PLUS V-DRIVE LUBRICANT

Description Part No.

PCM Power-Plus V-Drive Lubricant (1 qt. bottle) R190250

PCM BASIC CRUISE SPEED CONTROL SYSTEM

Description Part No.

PCM Basic Cruise Control Panel RA152008

Speed Control Interface Harness - 14 Ft RA121091B

L510010-11

55

ENGINE SPECIFICATIONS - 12

PCM MASTER ENGINE SPECIFICATIONS - 2011

MODEL CES/MPI HO303 CES/MPI EX343 CES/MPI ZR409/ZR450

Displacement 5.0L (305 CID) 5.7L (350 CID) 6.0L (366 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 9.67:1

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

WOT Operating RPM 4800-5000 5000 - 5300 5400 - 5600 Preferred WOT RPM 4900 5200 5500

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 5 psi (35 kPa) 5 psi (35 kPa) 5 psi (35 kPa) at Idle at Idle at Idle

Spark Plug P/N R030010 R030010 R030011 Spark Plug Gap 0.060 in. 0.060 in. 0.040 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 200° F (93.3° C) 200° F (93.3° C) 200° F (93.3° C)

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

Ground Ground Ground

Alternator Rating 100 Amps 100 Amps 100 Amps

Ignition Timing Not Adjustable Not Adjustable Not Adjustable

CAM Retard 15 + / - 2 degrees 15 + / - 2 degrees Not Adjustable

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

120 Ah 120 Ah 120 Ah

56

L510010-11

ENGINE SPECIFICATIONS - 12

ENGINE UNDER LOAD.

PCM MASTER FUEL PRESSURE SPECIFICATIONS - 2011

PCM MASTER WARNING/ALARM SPECIFICATIONS - 2011

IMPORTANT: FUEL PRESSURE MEASUREMENT MUST BE MADE WITH THE

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

MODEL HO303 EX343 ZR409/ZR450

ALL ALL ALL

STD. FCC Fuel Pressure - FCC 57-62 psi

Returnless to Rail (WOT)

Fuel Pressure - LPFP 7 - 9 psi 7 - 9 psi 7 - 9 psi

ALL ENGINES (WOT) (WOT) (WOT)

200°F 200°F 200°F 200°F 200°F 200°F

Check Gauges Lamp Check Gauges Lamp

240°F 240°F 240°F

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

MODEL HO303 EX343 ZR409/ZR450 HO303 CES EX343 CES ZR409/ZR450 CES

Over-Temperature DTC 116/217 DTC 116/217 DTC 116/217 DTC 116/217 DTC 116/217 DTC 116/217

Coolant

Engine Derates Engine Derates Engine Derates Engine Derates Engine Derates Engine Derates

Sensor MIL MIL MIL Check Gauges Lamp Check Gauges Lamp Check Gauges Lamp

and Buzzer and Buzzer and Buzzer and Buzzer and Buzzer and Buzzer

L510010-11

Exhaust Manifold

Water Temperature Not Not Not DTC 1415/1416/ DTC 1415/1416/ DTC 1415/1416/

Sensors Applicable Applicable Applicable 1417/1418 1417/1418 1417/1418

and Buzzer and Buzzer

Engine Derates Engine Derates

Low Oil < 5 psi @ idle / < 5 psi @ idle / < 5 psi @ idle / < 5 psi @ idle / < 5 psi @ idle / < 5 psi @ idle /

Pressure Sensor < 24 psi @ 4000 < 24 psi @ 4000 < 24 psi @ 4000 < 24 psi @ 4000 < 24 psi @ 4000 < 24 psi @ 4000

DTC 524 DTC 524 DTC 524 DTC 524 DTC 524 DTC 524

MIL MIL MIL Check Gauges Lamp Check Gauges Lamp Check Gauges Lamp

and Buzzer and Buzzer and Buzzer and Buzzer and Buzzer and Buzzer

57

ENGINE SPECIFICATIONS - 12

5.0 / 5.7 Liter

LH ROTATION

FRONT

1

3

5

7

1

7

3

5

2

4

6

8

2

4

6

c

6.0 Liter

LH ROTATION

FRONT

1

3

5

7

2

4

6

8

NO

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

ALL EX343 ALL ZR450

Spark Plug Type R030010 R030011

(1.52 mm) (1.02 mm)

Not Adjustable Not Adjustable

ALL HO303 ALL ZR409

Model

Spark Plug Gap

Ignition Timing

0.060 in. 0.040 in.

Fixed, Fixed,

FIRING ORDER:

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

Firing Order

(LH Rotation) (LH Rotation)

CAM Retard 15 + 2 degrees Not Adjustable

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

58

L510010-11

ENGINE STORAGE

IMPORTANT: This service should be performed by an Authorized PCM Premier dealer.

CAUTION

Refer to FLUSHING COOLING SYSTEM before proceeding.

1. Fill the fuel tanks with gasoline 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.

OUT-OF-SEASON STORAGE - 13

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

. 6. Turn off the ignition and remove the spark plugs.

Use an aerosol-type fogging solution and spray a sufﬁ cient amount of oil into each cylinder. (Follow the instructions for the storage oil used.) Turn the crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders.

WARNING

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

2. Remove, empty and clean the fuel ﬁ lter assembly. Reinstall with a new fuel ﬁ lter and gasket / seals. 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 element and gasket / seals.

WARNING

Accumulation of water and other fuel contaminants may form corrosive compounds that can damage the fuel ﬁ lter, and result in fuel leakage. Ethanol blended fuel may increase this risk. For this reason, annual replacement of the fuel ﬁ lter, at a minimum, is required to avoid risk of explosion or ﬁ re.

CAUTION

Excess storage oil in the engine’s cylinders can cause hydrostatic locking to occur, and severe damage to the engine.

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

8. 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.

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

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.

3. Run the engine and allow it to reach normal operating temperature (a minimum of 10 minutes). Shut down the engine and change the oil and oil ﬁ lter (See ENGINE MAINTENANCE).

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

L510010-11

59

OUT-OF-SEASON STORAGE - 13

DRAINING INSTRUCTIONS

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

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.

MPORTANT: 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.

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.

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

1. Remove all the drain plugs and/or hoses according to the correct application found in the WATER FLOW DIAGRAM section of this manual.

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

2. 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”.

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

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

60

L510010-11

OUT-OF-SEASON STORAGE - 13

RECOMMISSIONING AFTER STORAGE

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

WARNING

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

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

10. 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).

11. Open the seacock before starting the engine.

12. 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.

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

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.

L510010-11

61

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 ignition/starter fuse. Replace the fuse or the engine management system 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.

62

L510010-11

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.)

L510010-11

63

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”).

64

L510010-11

WATER FLOW DIAGRAMS - 15

From Sea

Water Pickup

4

3

1

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the hoses

may vary slightly depending on installation.

Drain Locations

- Engine Block Drains - Remove Knock Sensors

- Engine Circulating Water Pump Pipe - Remove Drain Plug

1

223

- Exhaust Manifolds - Remove Drain Plugs

- Transmission Cooler - Remove Inlet Hose

4

Figure 15-1 Direct Drive Raw-Water Cooling System HO303 / EX343

1

L510010-11

65

WATER FLOW DIAGRAMS - 15

2

From Sea

Water Pickup

Note: This diagram is for illustration purposes only. The actual

routing and/or shape of the hoses may vary slightly depending

on installation.

P

L

E

A

S

U

R

E

C

R

A

F

T

E

N

G

IN

EG

R

O

U

P

OWERPLU

S

R

A

T

I

O

1.48

M

A

D

E

INU

S

A

Raw Water

Drain Plug

1/2”

Square

PCM V-Drive

1

2

3

445

5

Drain Locations

- Engine Block Drains - Remove Knock Sensors

- Engine Circulating Water Pump Pipe - Remove Drain Plug

- Exhaust Manifolds - Remove Drain Plugs

- Transmission Cooler - Remove Inlet Hose

- VDrive - Remove Drain Plug

Figure 15-2 Vee Drive Raw-Water Cooling System HO303 / EX343

66

L510010-11

Drain Locations

- Heat Exchanger - Remove Drain Plug

- Exhaust Manifolds - Remove Drain Plugs

112

- Transmission Cooler - Remove Inlet Hose

3

WATER FLOW DIAGRAMS - 15

From Sea

Water Pickup

3

2

Note: This diagram is for illustration purposes only. The actual

routing and/or shape of the hoses may vary slightly depending

on installation.

Figure 15-3 Direct Drive Half-System HO303 / EX343

L510010-11

67

WATER FLOW DIAGRAMS - 15

1/2”

Square

4

PCM V-Drive

4

S

FT UP

LU P

RO

NUSA

1.48

MADEI

ENGINEG

O I

PLEASURECRA

T

POWER

A R

Drain Plug

Raw Water

From Sea

Water Pickup

3

1

Note: This diagram is for illustration purposes only. The actual

routing and/or shape of the hoses may vary slightly depending

on installation.

Drain Locations

- Heat Exchanger - Remove Drain Plug

- Exhaust Manifolds - Remove Drain Plugs

1

2

- Transmission Cooler - Remove Inlet Hose

3

-VDrive-RemoveDrainPlug

2

4

Figure 15-4 Vee Drive Half-System HO303 / EX343

2

68

L510010-11

5

3

From Sea

WATER FLOW DIAGRAMS - 15

Water Pickup

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the hoses

may vary slightly depending on installation.

Drain Locations

- Engine Block Drains - Remove Knock Sensors

- Engine Circulating Water Pump Pipe - Remove Drain Plug

- Exhaust Manifolds - Remove Drain Plugs

- Transmission Cooler - Remove Inlet Hose

1

223

445

- Exhaust System Corners - Remove Drain Plugs

5

3

1

Figure 15-5 Direct Drive CES HO303 / EX343

L510010-11

69

WATER FLOW DIAGRAMS - 15

1/2”

Square

PCM V-Drive

T

S

P

A

AF

S

R

PLU

C

8 4 .

RE EGROU

1

U

ADEINU AS E NGIN

M L E

O I

P

T

POWER

A R

6

Drain Plug

Raw Water

6

From Sea

Water Pickup

Drain Locations

- Engine Block Drains - Remove Knock Sensors

- Engine Circulating Water Pump Pipe - Remove Drain Plug

- Exhaust Manifolds - Remove Drain Plugs

- Transmission Cooler - Remove Inlet Hose

- Exhaust System Corners - Remove Drain Plugs

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the hoses

3

may vary slightly depending on installation.

1

223

445

- VDrive - Remove Drain Plug

6

5

3

Figure 15-6 Vee Drive CES HO303 / EX343

70

1

L510010-11

4

WATER FLOW DIAGRAMS - 15

3

2

4

1

Note: This diagram is for illustration purposes only. The actual routing and/or shape of the hoses may vary slightly depending on installation.

Drain Locations

- Transmission Cooler - Remove Inlet Hose

1

- Raw Water Pump - Remove Outlet Hose

2

- Heat Exchanger - Remove Drain Plug/Zinc Anode

3

Figure 15-7 Direct Drive Fresh-Water Cooling System ZR409 / ZR450

- Exhaust Manifolds - Remove Drain Plugs

4

L510010-11

71

WATER FLOW DIAGRAMS - 15

1/2”

Square

PCM V-Drive

5

T

S

F P U

LU

RA

USA

RO

IN

1.48

NEG

MADE

ENGI

O I

PLEASUREC

T

POWERP

A R

Drain Plug

Raw Water

5

Drain Locations

- Transmission Oil Cooler - Remove Inlet Hose

- Raw Water Pump - Remove Outlet Hose

- Heat Exchanger - Remove Drain Plug/Zinc Anode

- Exhaust Manifolds - Remove Drain Plugs

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the

hoses may vary slightly depending on installation.

1

22334

- VDrive - Remove Drain Plug

5

4

1

4

Figure 15-8 Vee Drive Fresh Water Cooling System ZR409 / ZR450

72

L510010-11

Heat Exchanger - Rear View

Shaft Seal

Fitting

Fresh Water

Drain

Raw Water

Anode

Drain/Zinc

3

WATER FLOW DIAGRAMS - 15

1

Drain Locations

- Transmission Cooler - Remove Inlet Hose

- Raw Water Pump - Remove Outlet Hose

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the

hoses may vary slightly depending on installation.

1

- Heat Exchanger - Remove Drain Plug/Zinc Anode

223

Figure 15-9 Direct Drive Full-Fresh ZR409 CES / ZR450 CES

L510010-11

73

WATER FLOW DIAGRAMS - 15

1/2”

Square

PCM V-Drive

4

T

S

F A UP

LU

R

P

C RO

NUSA RE EG

1.48

ASU

MADEI ENGIN

O I

PLE

T

POWER

RA

Drain Plug

Raw Water

4

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the

hoses may vary slightly depending on installation.

Drain Locations

- Transmission Oil Cooler - Remove Inlet Hose

- Raw Water Pump - Remove Outlet Hose

- Heat Exchanger - Remove Drain Plug/ZincAnode

- VDrive - Remove Drain Plug

1

22334

1

Figure 15-10 Vee Drive Full-Fresh ZR409 CES / ZR450 CES

74

L510010-11

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the

hoses may vary slightly depending on installation.

Drain Locations

- Transmission Cooler - Remove Inlet Hose

- Raw Water Pump - Remove Outlet Hose

1

22334

- Heat Exchanger - Remove Drain Plug/Zinc Anode

- Exhaust Manifolds - Remove Hose

WATER FLOW DIAGRAMS - 15

- Exhaust Corners - Remove Drain Plugs

5

1

WARNING

THE ENGINE EXHAUST SYSTEM MUST BE COMPLETELY DRAINED FOR WINTERIZATION.

Heat Exchanger - Rear View

FOR THE PROPER DRAINING PROCEDURE.

REFER TO THE SPECIAL INSTRUCTIONS PROVIDED

WARNING

FORTHEPROPER DRAININGPROCEDURE.

REFERTOTHE SPECIALINSTRUCTIONSPROVIDED

THEENGINEEXHAUST SYSTEMMUSTBE COMPLETELYDRAINEDFOR WINTERIZATION.

Drain/Zinc

Raw Water

Drain

Fresh Water

Anode

5

4

5

4

Fitting

Shaft Seal

Figure 15-11 Direct Drive Half-System ZR450 CES

L510010-11

75

WATER FLOW DIAGRAMS - 15

6

1

2

Fresh Water

Drain

PLE

ASU

RE

C

R

A

F

T

EN

GIN

EG

RO

UP

POWER

P

LU

S

RA

T

I

O

1.48

MADEI

NUSA

Raw Water

Drain Plug

1/2”

Square

PCM V-Drive

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the

hoses may vary slightly depending on installation.

Heat Exchanger - Rear View

3

Raw Water

Drain/Zinc

Anode

Shaft Seal

Fitting

4

5

1

2

3

4

5

6

Drain Locations

- Transmission Oil Cooler - Remove Inlet Hose

- Raw Water Pump - Remove Outlet Hose

- Heat Exchanger - Remove Drain Plug/Zinc Anode

- Exhaust Manifolds - Remove Hose

- Exhaust Corners - Remove Drain Plugs

- VDrive - Remove Drain Plug

WARNING

THEENGINEEXHAUST SYSTEMMUSTBE COMPLETELYDRAINEDFORWINTERIZATION.

REFERTOTHE SPECIALINSTRUCTIONSPROVIDED

FORTHEPROPER DRAININGPROCEDURE.

WARNING

THE ENGINE EXHAUST SYSTEM MUST BE COMPLETELYDRAINED FOR WINTERIZ ATION.

REFER TO THE SPECIAL INSTRUCTIONS PROVIDED

FOR THE PROPER DRAINING PROCEDURE.

76

Figure 15-12 Vee Drive Half-System ZR450 CES

L510010-11

HEATER CONNECTIONS - 16

WATER OUT

Remove plug from intake manifold and install proper barbed ﬁ tting. The plug is located toward the front of the intake (belt end) on the even cylinder side.

WATER RETURN

Remove plug from circulation pump and install proper barbed ﬁ tting. The plug is located on the side of the circulation pump.

Figure 16-1 5.0/5.7L All Applications

L510010-11

77

HEATER CONNECTIONS - 16

WATER OUT

Remove plug from supplied ball valve ﬁ tting and install proper barbed ﬁ tting. The ﬁ tting is located in the hose above the

heat exchanger on both CES and non-catalyst engines.

6.0L Catanium Exhaust System (CES) 6.0L Non-Catalyst

WATER RETURN

Remove plug from supplied ball valve ﬁ tting and install proper barbed ﬁ tting. The ﬁ tting is located in the U-tube at the front lower right hand portion of the engine, both CES and non-catalyst engines.

Figure 16-2 6.0L Applications

78

L510010-11

INSTRUMENTATION WIRING DIAGRAMS - 17

NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.

A

NOTE THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS.

: POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM

2-PIN WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS NUMBER NAME WIRE COLOR

A

1. VBAT RED/PURPLE

2. GROUND BLACK

8-PIN WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS NUMBER NAME WIRE COLOR

*1. *CHECK GAUGES LAMP GRAY/BLACK*

2. TACHOMETER GRAY

3. COOLANT TEMP TAN

4. BUZZER TAN/BLACK

5. IGNITION PURPLE

6. MIL GREEN/YELLOW

7. STARTER YELLOW/RED

8. OIL PRESSURE DARK BLUE

*CES ENGINES ONLY

TWIN ENGINE

MASTER/SLAVE

ENGINE

HARNESS

CONNECTOR

2-PIN BOAT

HARNESS

CONNECTOR

FUEL TANK

SOLENOID

CONNECTOR

8-PIN BOAT

HARNESS

CONNECTOR

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

SPEED CONTROL/

CAN BUS

CONNECTOR

Figure 16-1 Typical Instrumentation Wiring

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.

L510010-11

79

LITERATURE - 18

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.

80

L510010-11

FORMS - 19

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.

L510010-11

81

FORMS - 19

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:

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

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

2007*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

2008*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

2009*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

2010*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

2011*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission

Base Engine 1 year, 200 hours with exclusions.

Note: *** 2005-2010 Model Year Engines: The remainder of the original PCM limited warranty is transferable to a subse-

quent purchaser, provided the engine does not have in excess of 300 hours and is submitted to PCM within 30

days of the date of sale.

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: ________________________________________________________________________________

82

L510010-11

FORMS - 19

OPERATION AND MAINTENANCE LOG

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

Fire Extinguisher Checked Batteries Tested

Gal of Qts of Oil Oil Check Lay Up Launch

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

L510010-11

83

FORMS - 19

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

84

L510010-11

NOTES - 20

L510010-11

85

Make Owner and Dealer copies of the Registration Card, as required.

Mail original to Pleasurecraft Engine Group.

L585002

IMPORTANT

The checks as listed below are designed to insure the safety and satisfaction of you, the owner. By signing this form, the dealer certiﬁ es that he has checked the installation and operation of the engine and ﬁ nds it to be performing properly. The owner or his agent should perform similar inspections periodically to identify potential problems before they occur and have any suspected defects checked and/or corrected immediately.

Use Owner’s Copy for Warranty ID until Warranty Identi cation Card is received by Owner.

Owner’s Signature

Boat Make

Date

Length

3 Year Transferable Limited Warranty

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

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

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

REMEDIES

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

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

WARRANTY COVERAGE, TERM

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

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 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.

Hull Serial #

Predelivery Checklist

Check for Bulletins Engine Oil: Check Drive Lube: Check

All Fuel Lines: Conﬁ rm No Leaks

All Water Lines: Conﬁ rm No Leaks

Battery Rating, Charge, and Level: Check Control Adjustments: Conﬁ rm Proper Operation

All Drain Plugs: Conﬁ rm Proper Installation

Belt and Pulley: Inspect for Damage

Gauges: Check for Proper Operation

Record Propeller Size, Rotation and WOT WOT RPM_________Diameter_________ Pitch_________Rotation__________ Record Fuel Pressure, Idle ______ Record Fuel Pressure, WOT ______

Trouble Codes Checked Trouble Codes Cleared

Dealer Reviewed Warranty with Owner

Electrical Wiring: Check for Proper Installation

All Oil Lines: Conﬁ rm No Leaks

Engine Model No.

Engine Serial No.

Trans/Gear Serial No.

VDrive Serial No.

Owners Name

Owner’s Primary Mailing Address

City

Zip Code

State

Owner’s Primary Email Address

Selling Dealer

Selling Dealer Mailing Address

City

Zip Code

State

Premier Dealer No.

Date of Sale

Dealer’s Signature

Date

From:

MAIL TO:

WARRANTY DEPARTMENT

PLEASURECRAFT ENGINE GROUP

P.O. DRAWER 369

LITTLE MOUNTAIN, SC 29075

FIRST

CLASS

POSTAGE

This Page

Was Intentionally

Left Blank

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

PCM EX343 MPI (2011), Catanium CES 6.0L ZR450 (2011), ZR409 MPI (2011), Catanium CES EX343 (2011), Catanium CES HO303 (2011) Owner's Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual