OWNER’S OPERATION and MAINTENANCE MANUAL

A Division of

Thank you for your selection of Pleasurecraft (PCM) Marine Power for your boating needs. We welcome you to Team PCM, which puts you in the company of tens of thousands of boaters who have relied on Pleasurecraft inboards as their power of choice for over 20 years. When you chose PCM, you selected the utmost in premium power for your boating application. Pleasurecraft is the world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting edge technology. Over the years, we have introduced many breakthrough innovations that quickly became industry standards. The pyramidal exhaust system, light-weight transmission, computerized engine control and the Fuel Control Cell (FCC) are all PCM innovations. No matter which PCM model you purchased, you can be sure it is equipped with the latest in modern technology for added performance and durability.

READ THIS MANUAL THOROUGHLY
Before starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand any portion of the manual, contact your Dealer for clarification or assistance. Ask your Dealer for a demostration of actual starting and operating procedures. The descriptions and specifications contained in this manual were in effect at the time of printing. PCM Engines’ policy of continued improvement reserves the right to change specifications or design without notice and without obligation. This manual will cover the following PCM engines: Year 2002-2003 2002-2003 2003 2002-2003 2002-2003 Model 5.0L MPI 5.7L MPI 6.0L MPI 8.1L MPI 8.1L MPI (HO)

Part Number - L510010-03

Printed 11/02

TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................... 3-5 Registration Information ............................................................................................................... 3 3-Year Transferable Limited Warranty .............................................................................................. 4 Safety Information ...................................................................................................................... 5 Replacement Parts ........................................................................................................................... 5 Safety Warnings ......................................................................................................................... 5 BOATING RESPONSIBILITY .................................................................................................... 6-8 Carbon Monoxide Hazard ............................................................................................................ 6 Safe Boating Suggestions ............................................................................................................ 7 Water Wisdom ........................................................................................................................... 7 Operation and Maintenance .......................................................................................................... 7 Rules of the Road ....................................................................................................................... 8 ENGINE IDENTIFICATION ...................................................................................................... 9-10 Engine Identification .................................................................................................................... 9 Owner Identification and Registration Information ............................................................................. 9 2003 Model Identification / Advisory ............................................................................................. 10 ELECTRONIC FUEL INJECTION INFORMATION .......................................................................... 11 Electronic Fuel Injection System .................................................................................................. 11 Power Reduction Mode .............................................................................................................. 11 OPERATING INSTRUCTIONS ................................................................................................ 12-16 Engine Alarm System ................................................................................................................ 12 Instrumentation ........................................................................................................................ 13 Starting Engine (Fuel Injected Engines) ........................................................................................ 14 Shifting Transmission ................................................................................................................. 15 Stopping Engine ....................................................................................................................... 16 Freezing Temperature Operation .................................................................................................. 16 Operation in High Debris Areas ................................................................................................... 16 CONDITIONS AFFECTING OPERATION ................................................................................. 17-18 Trim and Weight Distribution ........................................................................................................ 17 Boat Bottom ............................................................................................................................. 17 Propeller Selection .................................................................................................................... 18 ENGINE BREAK-IN PERIOD ..................................................................................................... 19 25-HOUR ENGINE INSPECTION ................................................................................................ 20 FUEL REQUIREMENTS ............................................................................................................ 21 Gasoline Requirements .............................................................................................................. 21 Gasoline Containing Alcohol ....................................................................................................... 21 OIL REQUIREMENTS ............................................................................................................... 22 Engine Oil Recommendations ..................................................................................................... 22 Transmission and “V”-Drive Oil Requirements ................................................................................. 22 ENGINE MAINTENANCE ...................................................................................................... 23-51 Engine Maintenance .................................................................................................................. 23 Checking Fluid Levels ........................................................................................................... 23-24

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............................................................................................................................................................................................................. 28 Checking Coolant Level .............. 62-66 INSTRUMENTATION WIRING DIAGRAM ...................................................................TABLE OF CONTENTS Lubrication ....................................................................................................... 55 Battery Storage .............................................................................................................................. 27 Fresh Water Cooling System Sacrificial Zinc Anode ............ 54-57 Engine Storage .............................. 38 Accessory Drive Belt ................................................................................................................... 43-46 Engine Maintenance Log ....................................................................................................................... 26 Electrical System Fuses ........................................................... 37 Priming Fuel System ........... 34 Fuel Control Cell (FCC) Fuel System ..................................................................................................................................................................................................... 68 FORMS....................................................................................................... 73-75 2 ....................................................................................... 43 Engine Alignment ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 31 Filling Fresh-Water Cooling System ............................................ 29 Flushing Cooling System ................................................................................................................................................................................................................................................................................................................................................................................................. 33 Fuel System Description ............ 50 Transmission Fluid Capacities ................................... 57 TROUBLESHOOTING .................................................................... 36 Primary Fuel Filter ..................................................................... 30 Testing Coolant For Alkalinity .......................... 26 Battery .....................................Sea-Water Section ............................................. 48 Visual Inspection .......................................................................................... 36 Filter Element Replacement............................................................................................................................................................................................................................................................... 47 Maintenance Schedule ............. 51 ENGINE SPECIFICATIONS ........................................................................................................................... 34 Servicing the FCC .. 50 Engine Fluid Capacities ...... 69-72 NOTES ................................... 26 Ignition Fuse .... ENGINE OFF .................................................................................................. 56 Fitting Out After Storage .................................................................................................................................................................................................................................................................................................................................................... 58-61 WATER FLOW DIAGRAMS ..................................................................... 31 Draining Fresh-Water Cooling System ............................................... 52-53 OUT-OF-SEASON STORAGE .............................................. 26 Electrical System Wiring and Connectors ..................... 35 Draining the FCC Bowl.................................................... ENGINE OFF .................................................................................................................................................................................................................................................................. 39-42 Changing Oils ......................................................... 54 Draining Instructions ..................................................................................... 67 LITERATURE ............................................................................................................................................................... 38 Flame Arrestor ...................................................................................... 50 Filter Requirements ............................ 32 Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) ............................................................................................... 25 Electrical System Circuit Breaker(s) .........

and have implemented many of the ideas our customers have given us through this survey. you will be mailed your Warranty Card and a Customer Survey. We appreciate your feedback and encourage you to fill out the survey after you have had a chance to run your boat for several weeks. 3 . We sincerely wish you happy days on the water.INTRODUCTION . Again. pleasurecraft. We take this input very seriously.1 REGISTRATION INFORMATION Shortly after your purchase is registered with PCM.com. thanks for choosing PCM. You may also visit our website at www.

service under the terms of this Warranty will be performed by an authorized PCM dealer or distributor without charge for established flat rate labor or replacement parts. spark plugs. Further. to the first registered user.O. the term of this Warranty shall be the shorter of (a) a period of six (6) months from the date of delivery to the first registered owner or registered user or (b) the expiration of 200 hours of use. PCM makes no other express warranty to the extent that any additional warranty may be implied by law. gaskets. incidental or consequential damages. SC 29075 FAILURES EXCLUDED FROM WARRANTY This Warranty will not apply to any failure which results from accidents. (A) Water pump impellers are not covered by this Warranty. transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases. Prior authorization in writing must be obtained from PCM for any warranty repairs over $50. inconvenience. At the time that a claim for warranty service is made. agent or employee of PCM is authorized to grant any other or further warranty or incur any additional warranty obligation on PCM’s behalf. loss of use or loss of profits. or failure of components and/or assemblies that are warranted by PCM suppliers. All components of PCM products are covered under the PCM Warranty. or re-delivery charges. except for those components that are warranted by PCM’s suppliers. are warranted for a period of three (3) years from the date of delivery to the first registered owner or registered user. 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. in accordance with PCM’s warranty transfer policy. 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.1 3 Year Transferable Limited Warranty The Pleasurecraft Marine Engine Company (PCM) warrants its new products to be free from defects in material and workmanship under normal use and service conditions. The obligation of PCM hereunder shall be limited to the repair or replacement with new or remanufactured components. any damages for property damage. except only to the extent replaced or precluded by other law of mandatory application. Some States do not allow the exclusion or limitation of incidental or consequential damages. and construed and interpreted in accordance with. all of which shall remaining full force and effect. Any qualification or restriction contained herein which is prohibited by any law of mandatory application shall be deemed to be deleted herefrom. failure caused or contributed to by contaminated fuel. and lay up instruction. fire. OBTAINING PERFORMANCE UNDER WARRANTY PCM’s warranty registration form should be prepared by your selling dealer. 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.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. and all subsequent user who. or to any failure resulting from the use of parts. and.00. such deletion shall have no effect on the remaining provisions hereof. including without limitation. 3 Owner or user shall follow the instruction in the owner’s manual regarding operation. therefore. Items not covered under this warranty. cannot be honored until the product purchase date can be confirmed by PCM. haul out. repairs or improper delivery service. in accordance with PCM’s warranty transfer policy. by you. dealer. executed by you and the dealer and mailed. loss of income. mechanic travel time and mileage. Any questions concerning service. 4 Owner or user shall follow or comply with the maintenance schedule. all requested information recorded and that the selling dealer has signed the warranty registration.. carpets. 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. other than and those itemized below. the term of such implied warranty shall be limited to the warranty term stated herein. trailering. reliability or performance. for the period specified below: All components. This Warranty gives you specific legal rights. to PCM within 30 days after the date of purchase. cleaning. please write PCM at the address below. this Warranty shall not be effective and. and other items which are normally frequently replaced as part of routine maintenance. and you may also have other rights which vary from State to State. fuels. O-rings. moving of furniture. are warranted by the Industrial Engine Division of the Ford Motor Co. telephone expenses. operation limits. failure to follow maintenance or lubrication schedules. damage caused by any occurrence of an insurable nature. from the date of delivery of the PCM product to the parties outlined herein. painting. but not limited to. points. CHOICE OF LAW This Limited Warranty shall be governed by.INTRODUCTION . Drawer 369. towing. in the opinion of PCM. the laws of the State of Ohio. such as . P. (B) Seals. In case of commercial use. so the above limitations may not apply to you. sinking. a new owner’s registration card will be issued to you. communicate with PCM at the address listed below. failure resulting from the owner’s or operator’s failure to exercise due or normal care and precaution. This Warranty does not apply to any engine or drive which has been modified. the owner’s registration card should be presented to the person or entity providing warranty service. NO OTHER WARRANTY GIVEN The obligations set forth in the preceding paragraph are PCM’s sole obligation and owner’s exclusive remedy. If your dealer is unable to assist or if you relocate or are travelling or need a referral to your nearest dealer contact: Pleasurecraft Marine Engine Co. in accordance with PCM’s warranty transfer policy. launch and/or any other in and out of water expenses. abuse. oils or lubricants not suitable for use with the product and/or materials or parts not approved by PCM. removal and replacement and/or modification of any boat parts to facilitate repairs. and are not covered by this Warranty. so the above limitation or exclusion may not apply to you. . While failure to present the owner’s registration card will not prevent you from obtaining coverage hereunder. Authorized PCM dealers or distributors are entitled to be reimbursed by PCM for some or all of the expense of warranty repairs. and all subsequent user who. travel expenses. or repaired in such a manner as. at its option. Some States do not allow limitations on how long an implied warranty lasts. No distributor. parts or this Warranty should be directed to your selling dealer. in connection with the sale of its products. TERM This Warranty is extended only to the first registered owner or registered user. or indirect. or abnormal service or use. 2 Owner or user shall promptly mail the warranty registration to PCM after accepting delivery. other than items not covered by the Warranty. such as racing. WARRANTY COVERAGE. this Warranty will not apply to failure resulting from use of non-recommended lubricants or fuels. thus. lodging expenses. 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. or altered. or to any failure resulting from improper installation. If the owner’s registration card is not received within eight (8) weeks after the date of purchase. however. Little Mountain. lubricants. Charges for additional non-warranty work and/or additional dealer charges for labor relative to warranty work in excess of flat rate must be paid for by the owner. for a processing fee of $10. REMEDIES The obligations of PCM set forth in the first paragraph of this Warranty shall be the exclusive remedy for any breach of Warranty hereunder. expenses to deliver or pick up the product being warranted to and from the dealer. rental of substitute equipment of any type. failure caused by improper installation or misapplication of the engine or drive. Upon receipt of the warranty registration form. transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases. neglect. and fuel. and all subsequent user who. towing or operation in water of insufficient depth. In no event will PCM’s liability exceed the purchase price of the goods which is actually paid to PCM. carpenter work. improper adjustments. break-in. as outlined in the owner’s manual. OWNER’S RESPONSIBILITY Performance under this Warranty shall be conditioned upon the first 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. storage charges. lubrication. dockage charges. to affect its stability. PCM shall not be liable for any direct. (C) Components supplied by the Ford Motor Co. If the card is lost. transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases in non-commercial use. and (b) all claims of negligence or strict liability or both. PCM will issue to you a personalized owner’s registration card which will be mailed directly to you.

Coast Guard rules and regulations to minimize the possibility of fire or explosion hazard.S. Always request that genuine PCM Engines replacement parts be used in any repairs or maintenance being performed on your engine(s). DANGERS and WARNINGS are accompanied by the international HAZARD symbol: These “Safety Warnings” alone cannot eliminate the hazards that they signal. could cause a fire or explosion hazard and should be avoided. CAUTION Indicates a hazard which could result in damage to equipment. severe injury or high probability of death to the user if proper precautions are not taken. etc. failure or breakdown of equipment. This signal word is applied in extreme situations WARNING Indicates a potential hazard which could result in personal injury. ignition and fuel system components are designed and manufactured to comply with U.e. Coast Guard approved.) in the electrical. REPLACEMENT PARTS DANGER Electrical. automotive. WARRANTY NOTICE: Indicates a possible warranty exclusion. plus “common sense” operation. Use of replacement parts (i. are major accident prevention measures. IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily. after-market.S.INTRODUCTION . which are not U. 5 .1 SAFETY INFORMATION “Safety Warnings” and additional information or instructions are used to alert the installer/operator of possible safety hazards in performing certain service or maintenance procedures incorrectly or carelessly. Strict compliance with these warning instructions while performing service and maintenance procedures. SAFETY WARNINGS DANGER Signals serious damage. ignition and fuel systems.

In no way can this section cover all of the possible variables. DO NOT operate your engines until you have contacted your boat manufacturer. MD 21037-1416 www.uscgboating.com 410-956-1050 6 . generators. including how you can prevent carbon monoxide poisoning on recreational boats. contact: National Marine Manufacturers Association 200 East Randolph Drive Suite 5100 Chicago.). odorless and tasteless gas. etc.abyc. Do not rely on this section as the exclusive listing of measures to prevent the accumulation of carbon monoxide. wind direction. DC 20593 www. in and around boats is affected by vessel geometry. boat speed. closeness to other structures. is absolutely necessary to aid in the prevention of carbon monoxide build-up. 3069 Solomon’s Island Road Edgewater. propane.org 202-267-0984 American Boat & Yacht Council. Carbon monoxide accumulation. heaters and charcoal grills also produce carbon monoxide. oil. overall vessel design. smell it or taste it. IL 60601-6528 www. and many other variables. coal or wood is burned. To find out more about making boating safer. If you have any questions or concerns regarding the operation of your boat and carbon monoxide hazards. Proper and adequate air circulation. natural gas.BOATING RESPONSIBILITIES . open flame devices like cooking ranges.2 CARBON MONOXIDE HAZARD DANGER Carbon Monoxide (CO) is a colorless. Inc. around and throughout the boat. If an inspection reveals possible leaks. brain damage or death! Carbon monoxide is produced when anything that contains carbon.nmma. In addition. Consult your boat operators manual for detailed information on the inspection and/or maintenance of the exhaust system for your particular application. Prolonged exposure to carbon monoxide can lead to unconsciousness. Carbon monoxide is commonly found in the exhaust of internal combustion engines (boat power plants. You cannot see it. DO NOT operate your engine(s) until it can be serviced by a qualified technician.org 312-946-6200 United States Coast Guard Office of Boating Safety CG Headquarters G-OPB-3 2100 Second Street SW Washington. such as gasoline.

Tools necessary for minor repairs Spare propeller Anchor and anchor line First aid kit and first aid book Ship-to-shore radio. Follow the “Rules of the Road” when boating. Contact your local Coast Guard Auxiliary and take advantage of their seasonal boat inspections.BOATING RESPONSIBILITIES . Monitor the weather. 1-800-336-BOAT. and avoid.” Let someone know your destination and your expected time of return. Be sure your boat is equipped with the required safety equipment. and in Virginia. Approved fire extinguishers Signal devices: flares. File a “float plan. batteries. Always be on the alert and watch out for “the other guy. compass and chart of the area in which you are traveling Manual bilge pump and spare drain plugs Waterproof storage containers PCM Engines highly recommends that all power boat operators attend one of these courses. Know the signs of weather change and avoid severe weather and rough seas whenever possible. Boating safely and seamanship courses are offered by the following national and state organizations: • • • • Power Squadrons Coast Guard Auxiliary Red Cross State. return to your authorized PCM Engine Dealer. To help locate a course being offered near you. Do not consume alcoholic beverages or take illegal drugs when operating a boat.2 SAFE BOATING SUGGESTIONS The nation’s waterways are becoming increasingly crowded and. All lubrication and maintenance schedules must be adhered to assure optimum performance and dependability from your PCM engine. • • • • • • 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. etc. one for each person on board. Foundation’s toll-free national boating safety hotline. bulbs. hazardous areas. signal flag and horn or whistle PCM Engines’ “Onboard Kit.” plus spare fuses. When service and maintenance are required. DO NOT OVERLOAD! Make periodic checks of safety equipment onboard. provincial or local agencies in charge of water safety enforcement The following is a list of suggested safety equipment and spare parts which may be useful in case of an emergency: • • • • • Approved personal flotation devices (life jackets).” Plan and chart your course. Some state laws apply to boats as well as motor vehicles. Check with the Coast Guard and local government agencies as to the regulations and restrictions in your area. Be aware of. • • • • • 7 . in order to enjoy them safely. the operator should acquaint himself/herself with safe boating practices. OPERATION AND MAINTENANCE It is the owner’s/operator’s responsibility to perform all safety checks before operating his/her boat.S. 1-800-245-BOAT. spotlight. contact Boat U. Approved throwable personal flotation device for man-overboard protection.

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. and not numbered. STARBOARD (Right) . Keep all doors. Fisherman. and not numbered. remove all passengers. You are responsible for wake damage to other vessels and/or property. It indicates the starboard side of the channel when returning from sea. A can buoy with green and red horizontal bands (top band green). Divers and/or any other obstructions Keep Your Wake Under Control. pilot lights and smoking materials. Coast Guard Navigation Rules CG-169 Keep An Alert Lookout For: Bad weather. indicates an obstruction. Water skiers. Lighted Buoy (GREEN): This buoy has a quick flashing green light. The principal channel is to the left of the buoy when returning from sea. 8.54 MPH Storm Winds over 55 MPH Hurricane Winds over 63 MPH Do Not Fool With Fuel 1/2 pint of gasoline = 15 sticks of dynamite Storm Warning Signals . The quick flashing light indicates special caution required. Lighted Buoy (RED): This buoy has a flashing red light. Yield to boats approaching in this area. The principal channel is to the right of the buoy when returning from sea. 5. 4. 3. During fueling. keep it low • Passengers should only ride on the parts of the boat that are designed for that purpose • If water is rough.Leaving the harbor with green buoys to your right. Keep fuel lines and bilges clean. It is conical shape. It is cylindrical shape. 3. 4. 8 . Nun Buoy: This buoy indicates the starboard side of the channel when returning from sea. Small Craft Winds up to 38 MPH Gale Winds 38 . Can Buoy: This buoy indicates the port side of the channel when returning from sea. the color red and indicates even numbers. extinguish galley fires. Shut down all electronic gear. carry fewer passengers Observe the Rules of the Road PORT (Left) . (Red Right Returning) 1. 2. the color green and indicates odd numbers. Do not overload tanks. indicates an obstruction. Boat being overtaken has right of way. Overtaking boat must stay clear. 7.BOATING RESPONSIBILITIES . Boat Capacity • Load only to manufacturer’s specifications • Distribute load evenly. moor boat properly. Ventilate all components for a minimum of five minutes before starting engines.Entering the harbor with red buoys to your right. 2 5 Keep to Right in narrow channels. Red buoys always indicate the starboard side of the channel from seaward. Swimmers. Keep filling nozzles in contact with the fill pipe to prevent sparks.Pennants (by day) Lights (by night) 1.2 RULES OF THE ROAD Channel Buoy Guide The color of the paint is the only characteristic which has the same meaning on all buoys. hatches and ports closed. Other boats. It indicates the port side of the channel when returning from sea. A nun buoy with red and green horizontal bands (top band red). wipe away any spillage.S. 2. Secure the fill cap tightly. particularly upon entering or leaving harbor areas. 6.

ENGINE SPECIFICATION DECAL PCM MODEL RATIO HIGHWAY 76 EAST LITTLE MOUNTAIN S. MAKE MODEL FIRING ORDER FUEL PRESSURE 48-52 @ Idle 53-57 @ W. SERIAL THIS ENGINE CONFORMS TO ALL APPLICABLE U.S.7L 350 c. SC 29075 2. TRANSMISSION IDENTIFICATION PLATE THIS ENGINE CONFORMS TO ALL APPLICABLE U.0/5. ENGINE OIL RECOMMENDATIONS 15W-40 Above 50 degrees F 5W-30 Below 50 degrees F MARINE GEAR OIL RECOMMENDATIONS All PCM. 2 Figure 3-2 Engine Identification Tag Locations (5.i.060" FIRING ORDER: 18436572 ENGINE IDLE: 650-700 (Non-adjustable) When ordering service parts or obtaining information.O. GOVERNMENT STANDARDS FOR MARINE ENGINES IN EFFECT AT DATE OF MANUFACTURE. LITTLE MOUNTAIN. always give the engine model and the serial number.S.7L) PORT Engine Model Number: Serial Number(s): Gear Model Number: Serial Number(s): Boat Make: Boat Model: Hull Serial Number: Propeller Size: Ignition Key Number: STARBOARD 9 .ENGINE IDENTIFICATION . LITTLE MOUNTAIN. WHICHEVER OCCURS FIRST. SC 29075 3.d MULTIPORT FUEL INJECTION FUEL RECOMMENDATIONS Unleaded 89 Octane (Minimum) MAXIMUM CONTINUOUS CRUISE: 3800 RPM MAXIMUM ENGINE SPEED (WOT): 5000 RPM ELECTRICAL SPECIFICATIONS 12 Volts . 29075 SERIAL No OIL TYPE: DEXRON III MARINE POWER MAKE MODEL FIRING ORDER SERIAL CHECK OIL LEVEL DAILY OIL CHANGE AFTER FIRST 25 HOURS OF OPERATION AND EVERY 100 HOURS OR 12 MONTHS.C.3 ENGINE IDENTIFICATION 5. GOVERNMENT STANDARDS FOR MARINE ENGINES IN EFFECT AT DATE OF MANUFACTURE. This information can be found on the following decal. Warner and Hurth Transmissions: Dextron III ENGINES Important! See yours owners manual to insure that specifications for your engine have not changed or been ommitted from the specifications listed.T. ENGINE IDENTIFICATION DECAL 1 2 Figure 3-1 Engine Identification Decal 3 OWNER IDENTIFICATION AND REGISTRATION INFORMATION We suggest that you record the following information for quick reference when ordering parts or requesting service or warranty. IMPORTANT NOTE: WARRANTY IS VOID IF MAINTENANCE AND LUBRICATION INSTURCTIONS PER PCM MANUAL ARE NOT FOLLOWED. marine engines 1.Negative Ground IGNITION TIMING @ 1000 RPM 10 degrees (Non-adjustable) SPARK PLUG: Gap .

Rotation.Reverse / Reduction V . a “0” will appear in 10th space.1L (496 CID HO) (GM) (GM) (GM) (GM) (GM) 8th 9th 10th Spaces: DRIVE GEAR RATIO OR REDUCTION The drive gear ratio will appear in these spaces which identifies the production gear specs.0L (364 CID) G = 5.THROTTLE BODY INJECTION M . If the gear being identified does not have 3 digits.0L (305 CID STD) X = 8. The example gear number shown is a (1. ARE BOBTAIL ENGINES.7L (350 CID HO) I = 6.* 1st DIGIT INDICATES DECADE ENGINE WAS MANUFACTURED ( 3 = 1990.5:1 ) will appear as 150 *MODELS ENDING WITH “000000” IN PLACE OF DRIVE I.Pleasurecraft W .Right-Hand Rotation 10 .23:1). 4 = 2000.Borg-Warner V .1L (496 CID STD) Z = 8. 5th Space: DRIVE MANUFACTURER P .ENGINE IDENTIFICATION .Pleasurecraft Marine 2nd Space: FACTORY FRESHWATER / CLOSED COOLING X-Freshwater Cooled (Space Omitted If Raw Water Cooled ) 3rd Space: ENGINE ROTATION L . Right-Hand from Rear 4th Space: ENGINE TYPE A = 5. 5 = 2010 ) 2nd DIGIT INDICATES YEAR ENGINE WAS MANUFACTURED.Velvet Drive (cast iron units.D. 11th Space: IGNITION / FUEL TYPE USED D .Left-Hand Rotation R .Vee Drive / Reversed Risers F .D.3 PCM 2003 MODEL IDENTIFICATION / ADVISORY MODEL P X L A P R R 123 M SERIAL 430000 1st Space: MANUFACTURER P .Rotation. Example: ( 1.DISTRIBUTOR (Carb) E . Left-Hand from Rear R .MULTI-PORT FUEL INJECTION *SERIAL NUMBER I. Specify 71c or 72c) H .Hurth 6th Space: DRIVE FUNCTION / APPLICATION R .Full Reversing 7th Space: PROPELLER SHAFT ROTATION L .0:1 ) will appear as 100 ( 1.

the ECM allows fuel delivery through only half of the fuel injectors. Above 2500 RPM. normal engine operation is restored until the RPM exceeds 2500 RPM. the ECM will allow normal engine performance up to 2500 RPM. If either one of these inputs indicate an abnormal reading. The ECM is the decision center of the system. When in “Power Reduction” mode. Once the RPM is brought down below 1200 RPM.ELECTRONIC FUEL INJECTION INFORMATION . which allows precise control of fuel and spark delivery. followed by the illumination of an indicator lamp and/or sounding of the warning buzzer (if equipped). The fuel system components of the EFI system are: • The electric fuel pump • The throttle body assembly • The fuel injectors The fuel injection system is controlled by an Electronic Control Module (ECM). NOTICE: If it is not possible to safely shut off the engine. and electronically processes the information. The sensors that the ECM monitors are: • Engine Coolant Temperature (ECT) Sensor • Throttle Position (TP) Sensor • Manifold Absolute Pressure (MAP) Sensor • Knock Sensor (KS) System • Crankshaft Positioning (CKP) Sensor • Camshaft Positioning (CMP) Sensor • Intake Air Temperature (IAT) Sensor POWER REDUCTION MODE The ECM monitors engine oil pressure and engine coolant temperature whenever the engine is running. The feature allows maneuverability of the boat while removing the possibility of high engine speed operation until the problem is corrected. This is a feature that will help protect the engine during an overtemp or low oil pressure condition. Once returned to idle. calibrated to a specific RPM. the ECM will allow the engine to operate normally below 2500 RPM. the system will go into “Power Reduction” mode. The ECM constantly monitors information from various sensors on the engine. in order to control ignition timing and fuel delivery for optimum performance and fuel economy. to prevent engine damage from over-revving.4 ELECTRONIC FUEL INJECTION SYSTEM The PCM engines covered in this manual are equipped with an Electronic Fuel Injection (EFI) system. return the engine to idle speed. 11 . The ECM incorporates an engine overspeed protection.

OPERATING INSTRUCTIONS . 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. and that the engine have entered the “Power Reduction” mode as covered earlier in this manual.5 ENGINE ALARM SYSTEM (IF EQUIPPED) The PCM engine electronic system is programmed to control the engine alarm system. Observe the indicator lamps to locate the problem circuit. The alarm has a “self” checking feature programmed into the system. 12 . This system utilizes an audible alarm and/or optional indicator lamps to warn the operator of possible engine problems. If the alarm sounds during operation. This feature will sound the alarm for two short pulses upon initial start-up of the engine. The engine should be shut off to prevent damage to the engine. immediately throttle back to idle speed.

Tachometer .indicates the engine operating time 13 . Oil Pressure Gauge . Water Temperature Gauge .indicates the battery voltage and charging system voltage 6.indicates the engine oil pressure 5. Hour Meter .OPERATING INSTRUCTIONS . Engine Synchronizer (twin engines only) 3.5 INSTRUMENTATION Boat manufacturers install many different types of instrumentation on boats.indicates the engine coolant temperature 4. The following is a brief explanation of typical instrumentation found on most boats: 1. Voltmeter .indicates the engine RPM (revolutions per minute) 2. Become familiar with the instrumentation on your boat and be aware of abnormal operating conditions.

it is possible that the water is also leaking internally. move the throttle lever to a 100% open position (Figure 5-1). 5. When the engine starts. 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 Battery connections and water level in battery cells Accessory drive belt(s) Cooling system for leaks. Open the seacock. return the throttle lever back to the idle position. engine RPM will be slightly higher and will automatically decrease as the engine operating temperature increases. and subsequent overheating damage to the engine may result. 2. At this throttle position. 3.5 STARTING ENGINE (FUEL INJECTED ENGINES) WARNING Electrical. This could result in internal engine damage.S. It is very important to service these maintenance items as soon as a problem is indicated. 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. 7. Figure 5-2A Water Leaks IMPORTANT: The following items should be checked before starting the engine. check coolant level in recovery bottle. After performing the initial safety checks. 6. 4. NOTICE: Engine idle speed is controlled by the ECM and is based on the operating temperature of the engine. Check for signs of water leaks at the exhaust manifolds. 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.OPERATING INSTRUCTIONS . Open the fuel valve. The transmission is equipped with a neutral safety switch. Check for signs of external leaks Check for signs of external leaks • • • 14 . which will not allow the starter motor to operate unless the transmission is in neutral. If the water is leaking externally. The ECM will automatically regulate the fuel and control desired idle speed. Upon initial start-up. risers and elbows (Figure 5-2A). IMPORTANT: If the engine fails to start within 20-30 seconds. If equipped with freshwater cooling. Coast Guard rules and regulations to minimize risks of fire. Turn the battery switch ON (if equipped). Turn the ignition key to the start position. In the event the engine becomes flooded. ignition and fuel system components on PCM Engines are designed and manufactured to comply with U. Do not pump or open the throttle when starting the engine (Figure 5-1). the ECM will command the injectors to deliver no fuel during engine cranking. When the engine starts. proceed as follows to start the engine: 1. release the key. Place the remote control in Neutral position.

Shifting the transmission above 1000 RPM can severely damage the boat. transmission and engine. 10. Set the throttle lever at the idle position. Move the transmission lever completely backward to shift into Reverse gear. Check the temperature gauge to ensure the engine is operating within the normal temperature range. Move the transmission lever completely forward to shift into Forward gear. If oil pressure is not within specifications (see Engine Specifications). 9. 8. 11. Figure 5-2 Shift Control NEUTRAL REVERSE GEAR FORWARD GEAR 15 . Check voltmeter for proper charging system operation. immediately stop the engine and determine the cause. Check engine oil pressure immediately after the engine starts. 4.OPERATING INSTRUCTIONS . Move the transmission lever to the center detent position to shift into Neutral. oil.5 CLEAR FLOOD (100%) SHIFTING TRANSMISSION STARTING OR IDLE POSITION CAUTION Never shift the transmission into or out of gear unless the throttle is at the idle position. Figure 5-1 Throttle Position Setting NOTICE: If engine still fails to start. stop the engine immediately and determine the cause. water and exhaust leaks. contact your PCM Engines Dealer for service. Check the engine and transmission for fuel. 3. Allow the engine to reach normal operating temperature. 1. If the temperature is abnormally high. FULL THROTTLE (WOT) 2.

A minimum of 30 gallons per minute (114 liters per minute) flow rate is required. After the engine reaches idle speed. Flush the cooling system if in a salt water area. complete the following: 1. bring the throttle back to the idle position. Close the seacock. Before stopping the engine after extended high speed operation.5 STOPPING ENGINE When returning to the dock.OPERATING INSTRUCTIONS . turn the ignition key to the OFF position. 3. 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. if equipped. Refer to OUT-OFSEASON STORAGE for draining instructions. the cooling system must be protected after the engine is shut off to prevent freeze damage to the engine. FREEZING TEMPERATURE OPERATION If the possibility of freezing exists. Turn the battery switch OFF. a sea strainer should be installed in the water inlet hose to prevent debris from entering the cooling system. 2. 16 . The strainer used must be of sufficient size to allow an adequate supply of water for cooling the engine. After stopping the engine. OPERATION IN HIGH DEBRIS AREAS If the boat is to be operated in high debris areas. or whenever stopping the engine. 4. Close the fuel valve.

may cause the boat to bow steer (veer back and forth with little control) − − 17 . fuel economy and boat speed. In most areas. If the boat is docked for long periods of time. may cause the boat to porpoise When coming off plane. it increases the chances of following wave splashing into the stern of the boat BOAT BOTTOM To ensure maximum engine performance. − − − − • Trimming the bow down or shifting the weight to the bow (front) − Normally used for cruising (running) against a choppy wave condition.CONDITIONS AFFECTING OPERATION . acceleration onto plane and operating at slow planing speeds Will improve rough water ride and handling In extreme. it is advisable to coat the boat bottom with antifouling paint to prevent the build-up of marine growth. the bottom of your boat must be kept clean and free of marine growth and barnacles. the water inlets may become clogged with growth and will cause the engine to overheat.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). Marine vegetation may accumulate when the boat is docked and should be removed before operation. − 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. Contact your dealer for advice on these requirements in your area.

including full fuel and water.1L (STD) MP 8. optional equipment.0L MP 5. passengers.CONDITIONS AFFECTING OPERATION . 18 .7L MP 6. the propeller must be changed to prevent loss of performance. Operating the boat with an increased load will cause an RPM loss (additional equipment.0L MP 8. See ENGINE SPECIFICATIONS for rated full throttle RPM for your model engine. gross weight (total weight of the entire boat. Generally. If full throttle RPM is above or below the recommended range as stated in ENGINE SPECIFICATIONS. passengers and other miscellaneous gear) is one of the major factors and should be one of the primary considerations when selecting a propeller. A one-inch change in either the pitch or diameter of a given propeller will generally change engine RPM by 150 to 250 RPM. See NORMAL CRUISING SPEEDS in SPECIFICATIONS. NOTICE: These engines incorporate an RPM “REV LIMIT” in order to prevent the engine from over-revving. ENGINE RPM CHART Model MP 5.). Problems caused by WOT operation are considered abuse and are not covered under the PCM Warranty.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.1L (HO) Minimum Full Load 4400 4400 5000 4200 4800 Maximum 5000 5000 5200 4600 5000 • • CAUTION Prolonged WOT operation will shorten the life of your engine and could cause premature engine failure. 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. etc.

Proper engine break-in is essential to achieve maximum performance. contact your dealer and have the recommended 25-hour inspection done. the correct propeller selection can be confirmed. or running at the dock. Reduce throttle to 2800-3000 RPM and operate for a few minutes. the following operation guidelines must be adhered to: • After the engine is thoroughly warmed up. Oil consumption should decrease and become stabilized after approximately 100 hours of operation. but not exceed. the engine’s RPM should reach. but wide open throttle should not be sustained for more than 1 minute. and the speed should be reduced if abnormal readings become evident.ENGINE BREAK-IN PERIOD . This cycle can be repeated from time to time during the first 5 hours of operation. DO NOT EXCEED MAXIMUM RPM. At the end of your 25-hour break-in period. Thereafter. This is the owner’s responsibility. During the break in. • • CAUTION DO NOT attempt to break in any engine by prolong idling. During the break-in period. all gauges should be watched carefully. NOTICE: PCM Engines assumes no responsibility for the costs related to the 25-hour inspection.7 WARNING Use this procedure ONLY when conditions are such that it can be done in complete safety. 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. or at sustained full throttle during the first 5 hours of operation. The break-in period of your engine is the first 25 hours of operation. and cruise at or below this speed for 1/2 hour. use sustained wide open throttle in the event of an emergency. and the boat is underway. During the early part of the break in period. • Reduce the throttle to 2800 . The engine oil level should be checked often and oil added when necessary. 19 . longevity and minimum oil consumption. Reduce the speed to idle. (With a normal load aboard. (Bringing the engine speed from idle to wide open throttle will load the engine and assist in seating the piston rings). (RPM should cease climbing after 10 to 20 seconds). the maximum RPM as listed in the specifications section). especially during the break-in period.3000 RPM. open the throttle to wide open throttle until maximum RPM is reached. CAUTION DO NOT operate at full throttle in neutral at any time. Go to wide open throttle until maximum RPM is reached and operate for approximately 1 minute.

Check the throttle and the shift cable adjustments and check for freedom of movement. missing or damaged parts. damage and deterioration. damage and deterioration. This is the owner’s responsibility. it is recommended that the engine be given an inspection. • • • NOTICE: PCM Engines assumes no responsibility for the costs related to the 25-hour inspection.Inspect all the hoses for leaks.Inspect the entire exhaust system for leaks. The following maintenance should be performed: • • • • Change the engine oil and filter.Check for loose.25-HOUR ENGINE INSPECTION . starter and alternator mounting fasteners. Check all the fluid levels. Check the battery cables and connections. Check all the hose clamps for adequate tightness. Inspect the accessory drive belt(s) and check the tension. Check all the hose clamps for adequate tightness. 20 . Engine Assembly . Check and clean the primary fuel filter Check the engine alignment. Inspect the case for damage. Your boat dealer or a PCM servicing dealer should be contacted to perform the necessary checks and adjustments to ensure the proper engine performance. Exhaust System . Battery . • • • Cooling System . Pay close attention to engine mounts.8 After the first 25 hours of operation.Check the electrolyte level and specific gravity.

the engine should be evaluated by a PCM Engine service technician. The use of higher octane fuels in these engines. 21 . is considered misuse of the engine. fuel lines. swelling. CAUTION Fire and Explosion Hazard . and . The ignition timing set by the factory requires the use of a high-quality lead-free regular gasoline with the following octane specification. NOTICE: Some gasolines contain an octane-enhancing additive called methylcyclopentadlenyl manganese tricarbonyl (MMT).FUEL REQUIREMENTS . Replace any component that shows signs of leakage. either ethanol (ethyl alcohol) or methanol (methyl alcohol) is not recommended for use in your engine.87 GASOLINE CONTAINING ALCOHOL Gasoline containing alcohol.9 GASOLINE REQUIREMENTS WARRANTY NOTICE: Damage caused to the engine through the use of improper gasoline. besides added operating costs. Careful inspection of the entire fuel system including. Any sign of fuel leakage or deterioration must be repaired immediately before further engine operation. Some applications may require a higher octane fuel. heavy knock occurs. if ignited. fuel filters and all fittings is mandatory. can cause temporary performance loss. MINIMUM OCTANE RATING R + M/2 METHOD 87 If gasoline containing alcohol is used. If a slight pinging is heard during acceleration and the proper octane fuel is being used. and they should not be used. more frequent inspections of the complete fuel system are required. fuel tanks. low-quality or gasoline with an octane rating below the minimum requirements listed below. These particular applications will be noted. Such damage is not covered by the PCM Engines warranty. can cause serious bodily injury or death. it is considered normal. corrosion. Therefore. deterioration. Figure 9-1 Fuel Requirements NOTICE: Most PCM Fuel Injected engines are calibrated to operate on 87 octane fuel and maximum performance is obtained when using this fuel. and engine performance may be effected. but not limited to. hardening or softening. Pump Octane Number (R+M/2) (PUMP) . If a constant. low speed stalling) Corrosion of metal parts Excessive wear and damage to internal engine parts Fuel permeation through flexible fuel lines Deterioration of some nonmetallic materials • • UN 87 L E EAD $ D • • D DE LEA R UN GULA E R The adverse effects of alcohol are more severe with methanol and are worse with increasing alcohol content. These fuels may reduce spark plug life.Gasoline is extremely flammable and highly explosive. Gasoline containing alcohol will attract and hold moisture and may cause the following: • Hard starting and operating difficulties (vapor lock. the use of these fuels is not recommended. or if the presence of alcohol is uncertain. especially after periods of storage.

non-detergent oils or low quality oils specifically are not recommended. 22 . PCM Engines does not review. Oil Change Intervals (Common) Crankcase oil and oil filter change . approve or recommend such products. Engine Oil Requirements The following chart shows the recommended oil viscosity for various ambient temperature ranges: Prevailing Ambient Temperature Above 50˚F Below 50˚F Recommended A. whichever occurs first 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.P.P. Synthetics may offer advantages in cold temperature pumpability and high temperature oxidation-resistance. Classification & Viscosity SAE 15W-40 “SJ” SAE 5W-30 “SJ” Walters “V”-Drive Regular oil changes .OIL REQUIREMENTS . However.I.I. Classification and Viscosity Dexron III Automatic Transmission Fluid (ATF) or equivalent Dexron III Automatic Transmission Fluid (ATF) or equivalent Dexron III Automatic Transmission Fluid (ATF) or equivalent All Hurth Gear Transmissions IMPORTANT: The use of oils which contain “solid” additives. Their use does not permit the extension of oil change intervals.10 ENGINE OIL RECOMMENDATIONS Use of Supplemental Additives Engine oils meeting PCM Engines’ recommendations already contain a balanced additive treatment. Synthetic Oils • Synthetic engine oils are not recommended for use in PCM Engines. synthetic oils have not proven to provide operational or economic benefits over conventional petroleum-based oils in PCM Engines.Recommended intervals: • Initial oil change . whichever occurs first TRANSMISSION AND “V”-DRIVE OIL REQUIREMENTS Transmission and “V” Drive PCM Transmissions Recommended A. The use of supplemental additives which are added to the engine oil by the customer are unnecessary and may be harmful.1st 60 days or 25 hours of operation.Every 50 hours of operation or 120 days.

Splashing or agitation of oil also may cause it to become aerated. it is strongly recommended that a PCM Engines repair manual be purchased and read thoroughly. 1. ENGINE OIL DIPSTICK OPERATING RANGE DIPSTICK FULL MARK ADD MARK Figure 11-1 Engine Oil Dipstick (Typical) WARNING The machinery space must be closed anytime the engine is running to prevent injury to you or others on board. Rotating machinery can cause injury and even death if an accident should occur. the “FULL” mark on the dipstick. Before performing any maintenance or repair procedure not covered in this manual. Some procedures may be performed by the owner/operator while others should be performed by an authorized PCM Engines Dealer. Remove the dipstick. but not over. 3. Never operate the engine with the engine machinery space open while someone is in the machinery space. and reinstall it fully into the dipstick tube. will be drawn into the combustion chamber and burned. Stop the engine if running. Remove the dipstick and observe the oil level. 2. 23 . and may result in internal engine damage from lack of lubrication. Extreme care must be exercised if a problem exists that requires operation of the engine with the machinery space open. Never open the machinery space unless the engine is shut off and the engines rotating parts are stationary. (Figure 11-1). which will adversely affect engine performance and may lead to premature engine failure. The oil level must be between the “FULL” and “ADD” marks. Continuous operation under these conditions can cause carbon to form on combustion chamber surfaces. CHECKING FLUID LEVELS Engine Crankcase Oil CAUTION Do not overfill engine crankcase with oil. Allow approximately 5 minutes for the oil to drain back into the oil pan. add specified oil to bring the level up to. which will affect the oil pressure. subsequently. IT IS RECOMMENDED THAT UNCOVERED ENGINE OPERATION BE ATTEMPTED BY TRAINED AND QUALIFIED SERVICE PERSONNEL ONLY.11 ENGINE MAINTENANCE Refer to the MAINTENANCE SCHEDULE for a complete listing of required maintenance and the frequency at which it should be performed. as excess oil will be splashed by reciprocating engine parts onto the cylinder walls in greater quantity than the rings can control. wipe it clean.ENGINE MAINTENANCE . The oil. If the oil level is below the “ADD” mark. either closed or open.

3. 2. PCM Transmissions 1. If low. Replace the dipstick and tighten securely. The fluid level should be at the “FULL” or “MAX” mark. Observe the fluid level. Stop the engine and quickly check the fluid level to minimize the drain-back from the oil cooler. Engine must be running at operating temperature. add in small increments until the FULL mark is reached.11 Transmission Fluid Hurth Transmission CAUTION PCM Engines uses marine transmissions supplied by several manufacturers. Remove the dipstick by turning the T-handle counterclockwise. Repeat checking procedures as required until the fluid level is at the “FULL” or “MAX” mark. Operate the engine until the engine and the transmission reach operating temperature. With the engine running. The maintenance requirements can be different between these manufacturers. install the dipstick in all the way. Observe the fluid level. MAX Figure 11-2A Transmission Dipstick and Location FULL MARK Figure 11-2 Transmission Dipstick and Location 24 . once in reverse. and the prop shaft not turning. 1. 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 the fluid level is low. The dipstick should read FULL. Remove the dipstick by turning the T-handle counterclockwise. 5. WARNING Do not attempt to remove the transmission dipstick while the engine is running. 2. Shift at least once into forward. add the specified fluid through the dipstick tube. for the level to read above the FULL mark. If no maintenance manual is available.ENGINE MAINTENANCE . PCM Engines recommends that you contact your dealer service department for any required maintenance or service instructions. Remove the dipstick and check the fluid level. Hot transmission fluid could be sprayed from the dipstick hole. HURTH TRANSMISSION 6. 3. Replace the dipstick and tighten securely.23:1 TRANSMISSION DIPSTICK SHIFT LEVER DIPSTICK MIN. 4. 5. SHIFT LEVER PCM 1. then back to neutral. after the engine is turned OFF. It is normal. 4.

BALL JOINT CABLE CLIP LUBRICATION POINTS Shift Cable Lubricate pivot points and exposed cable (Figure 11-4) with SAE 30W-30 engine oil.ENGINE MAINTENANCE .11 LUBRICATION Throttle Cable Lubricate pivot points and exposed cable (Figure 11-3) with SAE 30W-30 engine oil. LUBRICATION POINTS Figure 11-4 Typical Shift Cable Figure 11-3 Typical Throttle Cable 25 .

first check that the shift lever is in neutral position. The fuse block is mounted to a bracket near the exhaust elbow under a weather-tight cover. If resetting is still not possible. The circuit breaker can be reset by pushing the “Reset” button IN after waiting a few minutes. consult a PCM Engine dealer to make necessary repairs. the circuit breaker will open and prevent electrical current flow. Should an electrical overload occur.ENGINE MAINTENANCE . disconnect all accessories which are connected to the main wire harness. deterioration or damage. If electrical components or wiring show signs of corrosion. Check for loose or disconnected lead wires and shorted circuits. If the main circuit breaker is not tripped. If the cause of the overload cannot be found. the cause for the high current draw must be found and corrected. The ignition fuse may be located on the instrument panel. check the battery and alternator connections and all other harness connectors on the main harness. Check the wiring diagrams supplied from the boat manufacturer for the exact location. FUSE BLOCK CIRCUIT BREAKER Figure 11-5 Typical Electrical System Circuit Breaker and Fuses IGNITION FUSE ELECTRICAL SYSTEM FUSES PCM engines utilizes fuses to control the fuel pump. check for blown ignition fuse.11 ELECTRICAL SYSTEM CIRCUIT BREAKER Main Circuit Breaker PCM engines are equipped with a circuit breaker which provides electrical overload protection for both engine and instrumentation wiring and components. If the engine will not crank when the ignition key is turned to the START position. ELECTRICAL SYSTEM WIRING AND CONNECTORS The electrical system wiring and connectors should be checked periodically for loose or dirty connections and damaged wiring. the fuse holder block or as part of the instrument wiring harness. ECM and fuel injectors. When this circuit breaker opens. 26 .

Remove the battery from the boat and recharge in a well ventilated area away from fuel vapors. Do not use jumper cables and a booster battery to start the engine. always remove negative (-) cable first. Periodically check the battery for signs of corrosion. When removing the battery cables. and then remove the positive (+) cable. follow these guidelines for the proper battery care. Do not recharge a weak battery in the boat. IMMEDIATELY flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible. then install the negative (-) cable.ENGINE MAINTENANCE . Repair or replace as necessary. When installing battery cables. Periodically check the electrolyte level. sparks and open flames. as this may cause damage to the alternator. Make sure that all connections are clean and secure. If this information is not available. • • 27 . If electrolyte is spilled or splashed on any part of the body. • Do not operate the engine with an open in the battery circuit. Follow maintenance instructions and warnings as supplied by the battery manufacturer. frayed battery leads or cracked case. • WARNING Hydrogen gases that escape from the battery when charging are highly explosive. install the positive (+) cable first. Add distilled water to bring up to the proper levels.11 BATTERY WARNING Battery electrolyte is a corrosive acid and should be handled with care. Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte.

C. If more than one half of the zinc is gone. Different geographic locations and water make-up can result in either high or low sacrificial requirements. The length of the zinc rod when new is approximately 1.ENGINE MAINTENANCE . replace with a new zinc anode. remove the plug and visually check the condition of the zinc rod.1L) 28 . A high rate of zinc anode consumption should also alert the owner to a possibility of an improperly wired boat accessory.W. Replace if more than 50% missing with Crusader Part #10972.5 inches. P/N 23627 FULL ADD Figure 11-6 Zinc Anode Location F. which would require complete checking by qualified service personnel. To check. Heat Exchanger (8. ZINC ANODE HEAT EXCHANGER PROTECTIVE ANODE Remove and check condition of zinc pencil every 30 days.11 FRESH-WATER COOLING SYSTEM SACRIFICIAL ZINC ANODE Located in the raw water side of the heat exchanger is a zinc anode which is marked by a decal.

FULL COOLANT RECOVERY TANK PRESSURE CAP ADD Figure 11-7 Checking Coolant Level (8. Coolant should be added ONLY to the reservoir when the system cools. Coolant must be at the top of the filler neck. Inspect the coolant recovery system for leaks. The recovery bottle collects coolant that expands with rising temperature. Hot coolant. Coolant Filler Neck Periodically. Replace if necessary. Coolant level should be at or slightly above the “ADD” mark on the bottle when the system is cold.ENGINE MAINTENANCE .11 CHECKING COOLANT LEVEL WARNING Do not remove cooling system filler cap when the engine is hot. remove the pressure cap from the filler neck to ensure the coolant recovery system is functioning properly. allowing the pressure to vent. check the gasket in the cap for damage. Allow the engine to cool and then remove the pressure cap slowly. under pressure. on a cool engine.1L) 29 . may discharge violently and cause severe burns. and would otherwise overflow from the system. Coolant Recovery Reservoir The “see-through” plastic reservoir is connected to the heat exchanger by a small hose. If coolant is low.

The sea-water pump impeller may be damaged and subsequent overheating damage may result. Suction created by the sea-water pump may collapse the flushing hose. ATTACH FLUSHING ADAPTER HERE CAUTION Do not run the engine above 1500 RPM when flushing. causing the engine to overheat.SEA-WATER SECTION To prevent silt and/or salt build-up in the cooling system (fresh or raw-water cooled). CAUTION Do not operate the engine without sufficient amount of water being supplied to the sea-water pump. Watch the temperature gauge while flushing to ensure the engine does not overheat.11 FLUSHING COOLING SYSTEM .ENGINE MAINTENANCE . Close seacock (if applicable) before removing inlet hose. Figure 11-8 Typical Sea-Water Inlet 30 . flush the sea-water section of the cooling system with fresh water at specified intervals.

It is recommended to replace the standard ethylene glycol coolant in the system every two years to prevent a build-up of harmful chemicals within the fresh-water system. coolant is alkaline and does not need to be replaced. If the litmus paper remains red. If red litmus paper turns blue. 2. Remove the pressure cap from the coolant filler neck and insert one end of the litmus paper into he coolant.ENGINE MAINTENANCE . or drain plug on circulation pump Drain plugs on the cylinder block (one on each side) − 2. laboratory.). Remove the following drain plugs to drain coolant from the fresh-water cooling system: − − Drain plug on heat exchanger Remove the large hose from the engine block water circulating pump. Obtain red litmus paper from a local supplier (drugstore. Check your local restrictions for proper disposal instructions of removed coolant. 31 . Reinstall the hose(s) on the water circulating pump and tighten the clamps securely. the coolant is not alkaline and must be replaced. Remove the following drain plugs to raw water from the fresh-water cooling system: − − − Drain plug on oil cooler Drain plug on heat exchanger Drain plug on the bottom of each exhaust manifold 3. 1. which can lead to internal corrosion and cooling system problems. 3. DRAINING FRESH-WATER COOLING SYSTEM NOTICE: To protect the environment. After system has drained completely. coat all the drain plugs with PerfectSeal (or equivalent) and reinstall in the proper locations. NOTICE: Refer to cooling system water flow diagrams for drain locations.11 TESTING COOLANT FOR ALKALINITY It is recommended that the coolant in the fresh-water section be tested each year for alkalinity. Coolant that is not alkaline has lost the effectiveness of its rust inhibitors. 1. dispose of coolant properly. etc.

Figure 11-9 F. DEX-COOL™ MUST NOT BE MIXED WITH CONVENTIONAL (CONTAINING SILICATE) ENGINE COOLANTS.W. the service interval will be reduced from 5 years to 2 years. System (8. When the system is full. the cooling system must be immediately drained and flushed. THEREFORE.1L) DEX-COOL™ can become contaminated by inadvertently topping-off with conventional coolant. adding conventional coolant to the system or even if fill/drain containers are shared between coolants. Remove the pressure cap. to protect the engine to the lowest temperature to which it will be exposed. The fresh-water cooling side of the cooling system must be filled with a 50/50 mixture of DEX-COOL™ (or equivalent.W. 2. If contamination occurs. Fill Riser Location (8.11 FILLING FRESH-WATER COOLING SYSTEM A new extended life engine coolant known as DEXCOOL™ is used in your engine(s). the fresh-water cooling section must be filled with a correct type of coolant and water solution.ENGINE MAINTENANCE . FULL ANTIFREEZE SOLUTION IMPORTANT: More than 50% antifreeze solution can contribute to an overheating condition. THE SERVICE CHANGE INTERVAL ON ENGINES BUILT WITH DEX-COOL™ IS 5 YEARS. BOIL AND FREEZE PROTECTION ARE MEASURED IN THE SAME FASHION AS CONVENTIONAL COOLANTS. See ENGINE FLUID CAPACITIES for system capacities. Start the engine and operate at idle speed (800-1000 RPM) to purge any air from the system.1L) 32 . TO MAINTAIN FULL CORROSION PROTECTION DURABILITY. ADD Figure 11-10 Filling F. No short-term damage will occur. and refilled with DEXCOOL™. Fill the system with antifreeze solution until the system is filled. FILL RISER • • FULL ADD TO FULLY REALIZE ITS MANY ADVANTAGES. IMPORTANT: If the engine is being placed in winter storage.C. DEX-COOL™ MUST NEVER BE MIXED WITH CONVENTIONAL COOLANTS.C. install the pressure cap. however. 3. It is imperative to note the following about DEX-COOL™ engine coolant: • • IT IS PINK IN COLOR TO DISTINGUISH IT FROM CONVENTIONAL COOLANT. which meets GM6277M) extended life antifreeze and water solution. properly mixed. Make sure that all drain plugs are properly installed. DEX-COOL™ IS AN ETHYLENE GLYCOL BASED PRODUCT. 1.

Install the end plates and the new gaskets onto the heat exchanger.0L) CLEANING SEA-WATER SECTION OF HEAT EXCHANGER . Start the engine and inspect for leaks. Remove the bolts securing the heat exchanger end plates. 2. Remove the end plates and gaskets. System (6.11 ANTIFREEZE SOLUTION Figure 11-10A Filling F. 3. Use compressed air to blow out loose particles. Install the bolts and tighten securely. You may use the following procedure for cleaning. 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).FRESH-WATER COOLED MODELS ONLY The sea-water section of the heat exchanger should be cleaned whenever there is a noticeable decrease in cooling efficiency. Apply PerfectSeal to both sides of the new gaskets. or. Clean the water passages in the heat exchanger by inserting a suitable-size wire brush into each passage.C.ENGINE MAINTENANCE . if the build-up of scale and mineral deposits is heavy. Clean the gasket surfaces on the end plates and the heat exchanger.W. 4. HEAT EXCHANGER PLATE COOLANT DRAIN PLUG BOLT GASKET RAW WATER DRAIN PLUG Figure 11-11 Heat Exchanger and End Plate Removal (Typical) 33 . 1.

WARNING Visually inspect unit for fuel leaks before operating the engine. controls the fuel pressure. provides the necessary fuel pressure and volume to maintain proper engine performance. 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. DO NOT operate the engine. Gasoline is extremely flammable and highly explosive under certain conditions. as residual pressure may be present. Fuel is fed into the FCC bowl by a low-pressure. Be sure the ignition key is off and do not smoke or allow open flame in the area while servicing. The fuel pressure regulator. returns to the FCC bowl. located on the fuel rail. The fuel delivered to the engine by the FCC is filtered by a filter and water separator element. Fuel exits the FCC bowl at two (2) locations.11 FUEL SYSTEM DESCRIPTION WARNING Extreme caution must be exercised when servicing the fuel system and/or replacing fuel filter. The highpressure pump. highvolume electric fuel pump. Wipe up any spilled fuel immediately. Use caution when removing or replacing components. not used by the engine. The fuel system operates under high pressure. cruise and acceleration fuel requirements of the engine. If fuel leaks are present. and provides the necessary filtration and water separation.ENGINE MAINTENANCE . fuel enters the FCC bowl from two (2) locations. recirculating fuel). the low-pressure pump (initial input) and the fuel return line from the fuel pressure regulator (unused. contact your service center immediately. and maintains a constant pressure across the fuel delivery system. Excess fuel. This pump flows fuel at a volume much greater than the fuel flow rate required of the high-pressure pump and engine demands. WARNING Make sure that there are no fuel leaks before closing the engine hatch. WARNING Extreme caution must be exercised when servicing the fuel system. mounted inside the FCC bowl. As indicated above. 34 . The FCC incorporates two (2) fuel pumps to provide an uninterrupted flow of fuel to your PCM marine engine. The FCC constantly has an ample supply of fuel to meet the idle. which surrounds the high pressure pump inside the FCC bowl. Fuel Control Cell (FCC) Fuel System The Fuel Control Cell (FCC) eliminates vapor lock and air ingestion caused by fuel tank slosh.

11 FUEL SUPPLY LINE FUEL RETURN LINE FUEL CONTROL CELL LOW-PRESSURE FUEL PUMP Figure 11-12 Fuel Control Cell (FCC) Fuel System (Typical) Servicing the FCC The frequency of draining the water or replacing the filter element is determined by the contamination level of the fuel. Read and follow all instructions before proceeding. 35 . DO NOT remove the FCC bowl unless servicing the filter element. or death. WARNING Improper use. Run the engine and check for fuel leaks after installation. otherwise contamination or bowl O-ring swelling may result. or when a loss of power is noticed (whichever occurs first). installation or servicing may cause an explosion or fire resulting in bodily injury. Replace the filter element at least once a year. This unit should only be serviced by a qualified technician.ENGINE MAINTENANCE . element replacement or draining the bowl.

Correct any leaks prior to operating the engine any further. Correct any leaks prior to operating the engine. Disconnect the two-wire electrical connector. ENGINE OFF 1. Push on new filter element (part number RP080026) over the electric fuel pump. Hold the 3/4” jam nut. CAUTION: Both fuel and water will drain from the FCC bowl. Using a strap-type oil filter wrench. 6. Disconnect the two-wire electrical connector. and drain the bowl contents into an approved container. Remove the fuel filter element from the suspended pump by gripping the fuel pump with one hand. located at the bottom of the FCC bowl.RING FUEL FILTER FUEL BOWL Filter Element Replacement. Slide the bowl downward over the suspended filter element. with a wrench. and drain the bowl contents into an approved container. as residual pressure may be present. ENGINE OFF 1. remove the old O-ring from the inside of the FCC bowl mounting head. Cycle the ignition key several times to run the electric fuel pumps and fill the FCC bowl with fuel. suitable for use with gasoline. Remove the 7/16” plug. Use caution when removing or replacing components. Draining the FCC Bowl. 3. to the threads of the 7/16” plug. The fuel system operates under high pressure. FUEL PUMP "O". 3. 4. Apply pipe sealant. remove the FCC bowl by turning it counterclockwise as view from the bottom. It may be necessary to pull the unit to one side in order to remove the FCC bowl. 5. 5. Tighten the 7/16” plug while holding the 3/4” jam nut with a wrench. 7. Using a pick made of soft material. located at the bottom of the FCC bowl.ENGINE MAINTENANCE . Start the engine and inspect for fuel leaks. Hold the 3/4” jam nut. with a wrench. 2. 2. 4. 6.11 Primary Fuel Filter WARNING Extreme caution must be exercised when servicing the fuel system. such as a toothpick. CAUTION: The mounting head O-ring groove may be damaged by using sharp steel tools to remove this O-ring. Reconnect the two-wire electrical connector. FUEL DRAIN Figure 11-13 Fuel Control Cell (FCC) 7. Inspect the drain plug area for leaks. and pulling the filter element downward with the other hand. 36 . Remove the 7/16” plug. CAUTION: Both fuel and water will drain from the FCC bowl.

ENGINE MAINTENANCE . Tighten the bowl firmly back into the mounting head with an oil filter wrench. Inspect the drain plug area for leaks. thread the FCC bowl into the FCC mounting head. 37 . 13. Grease taper and the threads on the FCC bowl and. to the threads of the 7/16” plug. suitable for use with gasoline. Start the engine and inspect for fuel leaks. Reconnect the two-wire electrical connector. Apply pipe sealant. 11. 10. Lubricate the new O-ring with a light grease and install the new O-ring into the FCC bowl mounting head. by hand. 12.11 8. 14. Correct any leaks prior to operating the engine any further. Cycle the ignition key several times to run the electric fuel pumps and fill the FCC bowl with fuel. DO NOT ATTEMPT TO SERVICE ANY OTHER PARTS ON THIS UNIT. 9. Install and tighten the 7/16” plug while holding the 3/4” jam nut with a wrench. Correct any leaks prior to operating the engine.

Turn ignition key OFF. Turn ignition key to ON position for 5 seconds. Priming Fuel System To prime the fuel system. CLAMP (NOT SHOWN) FLAME ARRESTOR THROTTLE BODY Figure 11-15 Flame Arrestor .1L (Typical) 38 .5. Remove the flame arrestor.8. cycle the ignition key 3 times using the following procedures: 1. the flame arrestor should be checked for blockage caused by dirt or other foreign material. Crank the engine until it starts or 30 seconds elapse. repeat the priming procedures. 2. 3.ENGINE MAINTENANCE . Repeat steps 1-3 three times. Loosen the clamp securing the flame arrestor to the air intake tube or throttle body. 4.11 WARNING Make sure there are no fuel leaks before closing the engine hatch. THROTTLE BODY FLAME ARRESTOR FLAME ARRESTOR FASTENERS Figure 11-14 Flame Arrestor .7L (Typical) FLAME ARRESTOR At specified intervals. If the engine does not start. Pause for 10 seconds. Reinstall the flame arrestor and tighten the clamp(s) securely. Clean the flame arrestor with solvent and dry with compressed air.

ENGINE MAINTENANCE - 11
DRIVE BELT INSPECTION CAUTION
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 The replacement of the drive belt requires the removal of the inlet hose from the sea-water pump. With the hose removed, it is possible for water to enter the bilge of the boat, and possibly sink it. ALWAYS plug the inlet hose securely to prevent this possibility from occurring.

DRIVE BELT REPLACEMENT (8.1L)
1. Remove the inlet and outlet hoses from the seawater pump, being careful not to allow the hose clamps to fall into the bilge. 2. Remove the bolt and washers that attach the sea-water pump to the bracket, being careful not to allow the bolt and washers to fall into the bilge. 3. Loosen the bolts that attach the bracket to the engine block until a gap, large enough to pass the belt through, is created. 4. Note the routing of the belt before removing.

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

ALTERNATOR PULLEY

BELT TENSIONER

CIRCULATION PUMP AND ALTERNATOR DRIVE BELT

CIRCULATION PUMP PULLEY

IDLER PULLEY (if equipped)

CRANKSHAFT PULLEY

Figure 11-16 8.1L Accessory Drive Belt Configuration

39

ENGINE MAINTENANCE - 11
7. Compress the belt tensioner, and slide the belt over the tensioner pulley. Release the tension slowly to tension the belt. 8. Position the bracket onto the sea-water pump anchor boss, and install the flat washer, lock washer and bolt to the pump. 9. Tighten the bracket-to-engine block attaching bolts to 18 lb. ft. 10.Tighten the bolt that secures the sea-water pump to the bracket to 12 lb. ft. 11.Install the inlet and outlet hoses to the sea-water pump. Position the hoses and clamps so that the clamps are clamping on the pump side of the fitting bead. Tighten the clamps securely.

Figure 11-17 Belt Tensioner (8.1L) 5. Using a 15 mm box wrench or socket, turn the belt tensioner to relieve the tension on the belt. Slide the belt off of the pulleys and through the gap between the sea-water pump and the bracket. Release the tensioner slowly to prevent the tensioner from snapping against its stop, and possibly causing damage to the tensioner. 6. Slide the new belt through the gap between the sea-water pump and the bracket. Slide the belt onto the pulleys using the same routing as noted prior to removal.

40

ENGINE MAINTENANCE - 11
6.0L ACCESSORY DRIVE BELT
The PCM 6.0L engine uses a single serpentine belt to drive the engine water circulation pump, sea-water pump and the alternator.

DRIVE BELT REPLACEMENT (6.0L)
1. Note the routing of the belt before removing. 2. Using a 15 mm box wrench or socket, turn the belt tensioner to relieve the tension on the belt. Slide the belt off of the pulleys. Release the tensioner slowly to prevent the tensioner from snapping against its stop, and possibly causing damage to the tensioner. Figure 11-19 Belt Tensioner (6.0L)

Alternator

3. Slide the new belt onto the pulleys using the same routing as noted prior to removal. 4. Compress the belt tensioner, and slide the belt over the tensioner pulley. Release the tension slowly to tension the belt.

Belt Tensioner

Idler

Circulation Pump

Raw Water Pump

SERVICING RAW WATER PUMP IMPELLER (6.0L)
The raw water pump impeller should be serviced every 50 hours, or once a year, whichever occurs first. See Maintenance Schedule.

Crankshaft Pulley

A
Figure 11-18 6.0L Accessory Drive Belt Configuration

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

41

The belt should depress 1/2 in. ACCESSORY DRIVE “V”. (13 mm). 1/2" DEFLECTION ADJUSTMENT BOLT ADJUSTMENT BOLT RAW WATER PUMP RAW WATER PUMP BELT 1/2" DEFLECTION ADJUSTMENT BOLT RAW WATER PUMP ALTERNATOR BELT Figure 11-18 Drive Belt Location and Adjustment (5.7L ENGINE) Check the drive belt tension by pressing down on the belt midway between the two pulleys.7L) 42 . Apply required pressure with a pry bar.0L / 5. If depression is more than allowable.11 WARNING Engine must be shut OFF and the ignition key removed before inspecting the drive belt(s). glazing or deterioration. adjust the tension by loosening the adjustment bolt and the pivot bolt. If the belt(s) shows signs of cracking.ENGINE MAINTENANCE . tighten the adjusting bolt securely. Tighten the pivot bolt. While maintaining pressure. replace with new belt(s). The drive belt(s) should be checked periodically for condition and tension.BELT(S) (5.0/5. or 1/2 in breaker bar. to tighten the belt tension.

IMPORTANT: Change the engine oil when the engine is warm from operation. using an oil filter wrench if necessary. 2. through the oil fill location on the valve cover (Figure 11-20).00. Start the engine and operate for 5 minutes to circulate the oil throughout the engine. Install the oil filter securely by hand. 6. Coat the sealing ring. or causes sludge or emulsion beneath the surface of the water. Violators are subject to a penalty of $5. The engine and transmission oils should be changed prior to placing the boat into storage. at specified intervals. 43 . Check the oil level and add oil. 4. DIPSTICK CONTAINER Figure 11-19 Engine Oil Removal 3. is covered with an oil filter bypass adapter. 1. OIL FILL CAP Figure 11-20 Engine Oil Fill (8.000. if needed. Check entire system for leaks. DO NOT overtighten. The engine oil filter is remote mounted. to bring the engine oil to the proper level. remove the dipstick and install a crankcase oil pump onto the dipstick tube (Figure 11-19).1L) 5. or discoloration of the surface of the water. Refer to the MAINTENANCE SCHEDULE for oil change intervals. Fill the engine with the recommended oil. see OIL REQUIREMENTS. Remove the oil pump from the dipstick tube. Discard the old filter and sealing ring. With the engine at normal operating temperature. Pump the oil from the engine until the crankcase is empty. if such discharge causes a film or sheen upon. especially around the oil filter.ENGINE MAINTENANCE . Stop the engine and wait 5 minutes to allow the oil to completely drain down. Warm oil flows more freely. and allows more foreign material and impurities to be removed.11 CHANGING OILS OIL PUMP 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. on the new filter. Remove the oil filter by turning it counterclockwise. Insert the discharge hose into a suitable container. with a light coating of clean engine oil. where the filter is normally mounted. DO NOT remove this adapter when changing the oil. The engine block location. The transmission oil change should be performed by an authorized dealer.

align the engine to the shaft. then place the shaft in the middle of the movement. On these installations. Center the propeller shaft in the shaft log as follows: • 3.003 in. This applies to installations with solid couplings. 2.ENGINE MAINTENANCE . and coupling faces are parallel within 0. With the propeller shaft in the middle of the shaft log. Check the mating surfaces on the transmission and the propeller shaft couplings.11 ENGINE ALIGNMENT CAUTION • Engine must be properly aligned. 1. or vibration. then place the shaft in the middle of the movement. fuel tanks full and with a normal load on the boat. noise and damage to the transmission output shaft oil seal and bearings may result. Figure 11-21 Shaft Mating Surface Check 44 . with no resistance. Move the shaft to the port and then to the starboard as far as the shaft will move. use a straight edge to check the centerline alignment. Check that the coupling center lines align by butting the propeller shaft coupling against the transmission coupling. The shoulder on the propeller shaft coupling face should engage recessed on the transmission coupling face. NOTICE: Some propeller shaft couplings may not have a shoulder on the mating surface. • IMPORTANT: Engine alignment MUST BE RECHECKED with the boat in the water. Push down and then lift the propeller shaft as far as it will move. Make sure they are clean and flat. Engine must be aligned so that the transmission and the propeller shaft coupling center lines are aligned.07 mm). as well as flexible couplings. (0.

Check for any angular misalignment. Hold coupling faces tightly together and check for a gap between the coupling faces. Figure 11-23 Angular Alignment 45 . (0. at 90-degree intervals.ENGINE MAINTENANCE . with a 0.07 mm) feeler gauge.003 in.11 Figure 11-22 Centering Propeller Shaft 4.

4 mm) from the mounting brackets on any of the mounts. Tighten the coupling attaching bolts and nuts to the correct specifications. LOCKING NUT FASTENER TORQUE SPECIFICATIONS Location Engine Mount to Stringer Propeller Trunnion Bolts Figure 11-25 Mount Adjustment Lb-Ft (N.07 mm) out of parallel. to obtain the proper alignment. After the adjustment is complete. as necessary. Move the engine to the left or right.m) Securely 50 (68) 45 (61) 46 . (25.ENGINE MAINTENANCE .0 in. tighten the locking nut. 7. (0. If the coupling center lines are not aligned.003 in. adjust the engine mounts as follows: • UP or DOWN ADJUSTMENT: Loosen the locking nut. LOCKING NUT ADJUSTING NUT Figure 11-26 Engine Extension • LEFT or RIGHT ADJUSTMENT: Loosen the trunnion clamping bolt and the nut on all four mounting brackets. After the engine has been properly aligned. Connect the propeller shaft coupling to the transmission coupling.11 5. secure the engine mounts. Turn the adjusting nut or the adjusting bolt in the direction required to raise or lower the engine. MAX (25 mm) IMPORTANT: Both the front mount (or rear mount) adjustments must be turned equally to keep the engine level from side to side. or if the coupling faces are more than 0.0 in. 6. TRUNNION BOLT 1. Figure 11-24 Mount Adjustment ADJUSTING BOLT IMPORTANT: The large diameter of the mount trunnion MUST NOT extend over 1.

11 ENGINE MAINTENANCE LOG Date Maintenance/Repair Operating Hours 47 .ENGINE MAINTENANCE .

oil.Check and adjust if necessary Ignition Timing .ENGINE MAINTENANCE .Check (if equipped) Cooling System .Clean and inspect condition Engine Assembly (complete) .Clean and inspect X X X X X X X X1 X X X X X X X X1 X X O O O X X X X X X O O X X X X2 X X X 48 .Check for loose or dirty connections and damaged wiring Flame Arrestor and Crankcase Ventilation System .Not Adjustable Battery .Check condition and tightness of all hose clamps Cooling System .Check for obvious leaks (water. Inspect case for damage.Engine crankcase Check oil level .Inspect condition and check tension Exhaust System .Check for water leaks at the manifold.Check condition and tightness of all hose clamps Exhaust System .Check electrolyte level and specific gravity.Check for loose. starter and alternator mounting fasteners) Change engine oil and filter Engine Alignment .Replace raw water pump impeller Drive Belt . missing or damaged parts (especially engine mounts. riser and elbow gaskets Ignition System and Spark Plugs . fuel and exhaust) Remote Control and Steering System Check for proper operation Sea Strainer .11 MAINTENANCE SCHEDULE After 1st 25 Hrs of Operation Every 50 Hours of Operation Every 100 Hours of Operation Location and Service Check Daily Once Each Year Check coolant level .Transmission Engine Assembly (complete . Electrical System (complete) .Fresh-water cooled models only Check oil level . Check cables and connections.

Service or replace Transmission and “V” Drive . swelling.Use Dexron III automatic transmission fluid All Walters “V” Drive transmissions .Flush sea-water section Notes: (X) Denotes service to be performed by the owner/ operator (O) Denotes service to be performed by an authorized PCM Engines dealer (A) Use SAE 30 engine oil 3 1 As required 3 (X) At least once each year (X) Every five years Every 30 days 3 (X) Fresh water areas .Use SAE 80W-90 gear oil (D) Use WD-40 penetration oil or equivalent See COOLANT SPECIFICATIONS. every 100 hours of operation or 120 days (whichever occurs first).C) and clean strainer.ENGINE MAINTENANCE . In salt-water areas. every 25 hours of operation or 30 days (whichever occurs first).Check coolant for alkalinity Fresh-water cooled models .Inspect and lubricate (A) Fuel Filters .spray with rustpreventative oil (D) Cooling System (SALT WATER AREAS ONLY) .Use Dexron III automatic transmission fluid (C) All Velvet “V” Drive transmissions . 49 . Requires more frequent inspection if used in extremely salty. every 50 hours of operation or 60 days (whichever occurs first).Heat exchanger and cooler .Every 60 days (X) Salt water areas . polluted or mineral-laden waters. every 50 hours of operation or 60 days (whichever occurs first).Change fluid (B.Every 30 days (X) After use each day (X) In fresh-water areas. 4 (B) All Velvet Drive and Hurth transmissions . weather checking or other signs of deterioration Shift and Throttle Cable Linkage .Use Exxon Spartan EP-68 or SAE 30 engine oil All PCM “V” Drive transmissions .check condition Engine Assembly Exterior Surfaces . if equipped O O Hurth Only X X X1 X O O MAINTENANCE SCHEDULE (cont’d) Fresh-water cooled models . 2 In fresh-water areas.Clean sea-water section Fresh-water cooled models .11 MAINTENANCE SCHEDULE (cont’d) After 1st 25 Hrs of Operation Every 50 Hours of Operation Every 100 Hours of Operation Location and Service Check Daily Once Each Year Hoses (all) .Change coolant Zinc Anodes .Inspect for cracks. In salt-water areas.

Check the transmission fluid level at operating temperature and immediately after shutdown of the engine.35 L) TRANSMISSION FLUID CAPACITIES Model PCM.65 L)1 23 Quarts (21.42 L) Type DEXRON III DEXRON III DEXRON III DEXRON III SAE 30 1 .1L 4 Quarts (3. Spray paint may be obtained from your local PCM Engines dealer.2 Walters RV-36D V-Drive All Models 2.7L MP 6. All Ratios 1. nicks and corrosion damage to the exterior finish of the engine.8 L)1 5 Quarts (4.0L / 5.26 .85 L) 18 Quarts (17.5 .73 L) 1.0 Quarts (1.9 L) 2. Touch up scratches.23:1 Ratio 1.0 Quarts (1. Always use the dipstick to determine the exact quantity of oil required. Inspect the complete engine assembly for obvious fuel. 50 . 1. Most often. Check the electrical system for loose or dirty connections or damaged wiring. Check for loose.Capacities are dependent on installation angle.75 L)1 7 Quarts (6. V-Drive). All Ratios 1. Check all hose clamps for adequate tightness.01 L) 33 Quarts (31.9 L) 4.5.79 L) 4.11 VISUAL INSPECTION It is important for the owner/operator to visually inspect the complete engine assembly at regular intervals.0L MP 8. 2 .ENGINE MAINTENANCE .2 PCM.0 Quarts (3. damaged or missing parts. and may not include capacity needed for transmission cooler and oil lines. ENGINE FLUID CAPACITIES Model Crankcase Oil Capacity W / New Filter Fresh Water Cooling System Capacity MP 5. Protect engine finish from corrosion by periodically spraying the engine exterior finish with a rust preventative oil (such as WD-40).2 Hurth (Exc. 1:1 Ratio 1. water or exhaust leaks. costly repairs can be avoided if potential problems are corrected before there is a failure.2 Hurth V-Drive.0 Quarts (4.4.5 Quarts (1. oil. Oil capacities are approximate.

R077001 RP080026 51 .ENGINE MAINTENANCE .11 FILTER REQUIREMENTS Description Oil Filter (remote-mounted) Fuel Control Cell (FCC) Fuel Filter Element Part No.

60 psi (172 .160 psi (896 .5000 3800 650 (Not Adjustable) 25 .1103 kPa) 130 . (107.414 kPa) 10 psi (69 kPa) at Idle 34-47 psi (234-325 kPa) RWC 160˚F (61.1L (HO) (425 HP) ENGINE SPECIFICATIONS .60 psi (172 . (88. (101. (95.4600 130 .3 mm) 3.48 in.370 in.4:1 9.75 in.1L (STD) (385 HP) MP 8.80 psi (172 .4:1 130 .160 psi (896 .0L (275 HP) 5.1L (496 CID) 8.1:1 130 .1103 kPa) 4400 .0 mm) 4.60 psi (172 .6 mm) 4.160 psi (896 .622 in.160 psi (896 .0 mm) 4. (107.0 mm) 9.0 mm) 3.60 psi (172 .7˚C) FWC 170˚F (76.3 mm) 9.160 psi (896 .ENGINE SPECIFICATIONS MP 5.0007 in. (88.1:1 3.414 kPa) 10 psi (69 kPa) at Idle 55-62 psi (379-427 kPa) 55-62 psi (379-427 kPa) 10 psi (69 kPa) at Idle 10 psi (69 kPa) at Idle 55-62 psi (379-427 kPa) 25 .7L (330 HP) MP 6.7˚C) 12 Volt Negative (-) Ground 70 Amps 70 Amps 650 CCA (Minimum) 120 Ah 650 CCA (Minimum) 120 Ah 12 Volt Negative (-) Ground 70 Amps 650 CCA (Minimum) 120 Ah 4800 .0L (364 CID) 8.7˚C) FWC 160˚F (76.7˚C) FWC 170˚F (76.25 in.618 mm) 4.414 kPa) 25 .95 mm) 4. (111.7˚C) FWC 170˚F (76.25 in. (101.7˚C) 12 Volt Negative (-) Ground 70 Amps 650 CCA (Minimum) 120 Ah 12 Volt Negative (-) Ground MODEL (Horsepower) Displacement Bore Stroke Compression Ratio Compression Pressure WOT Operating RPM Cruising RPM (Max) Idle RPM (In Gear) Oil Pressure @ 2000 RPM Minimum Oil Pressure Fuel Pressure Thermostat Electrical System Alternator Rating Battery Rating .0 in.7˚C) 12 Volt Negative (-) Ground 70 Amps 650 CCA (Minimum) 120 Ah MP 5.1103 kPa) 4400 .12 52 RWC 160˚F (61.7L (350 CID) 6.7˚C) FWC 170˚F (76.414 kPa) 10 psi (69 kPa) at Idle 34-47 psi (234-325 kPa) RWC 160˚F (61.5000 3600 650 (Not Adjustable) 650 (Not Adjustable) 25 .1103 kPa) 130 .48 in.1L (496 CID) 4.1103 kPa) 9. (92.7˚C) RWC 160˚F (61.0L (370 HP) MP 8.370 in.552 kPa) 650 (Not Adjustable) 3800 4100 3600 650 (Not Adjustable) 25 .4:1 9.95 mm) 5. (111.5000 5000-5200 4200 .0L (305 CID) 3.

(1.0 / 8.12 5. Not Adjustable 1-8-7-2-6-5-4-3 (LH Rotation) Ignition Timing Firing Order 53 .52 mm) Fixed.0 / 5.TJ14R-P15 0.PZTR5A-15 0.1 Liter LH ROTATION FRONT 2 4 5 6 5 6 7 8 8 7 8 NO DISTRIBUTOR Rotation FLYWHEEL END OF ENGINE ALL V-8 MODELS FIRING ORDER: 1-8-4-3-6-5-7-2 c 5 6 3 4 7 2 1 FIRING ORDER: 1-8-7-2-6-5-4-3 Figure 12-1 V-8 Firing Orders TUNE-UP SPECIFICATIONS Model Spark Plug Type Spark Plug Gap MP 5.ENGINE SPECIFICATIONS .52 mm) Fixed.52 mm) Fixed.7 Liter LH ROTATION FRONT 1 3 2 4 1 3 6. (1.060 in.1L (HO) (425 HP) Denso . (1. Not Adjustable 1-8-7-2-6-5-4-3 (LH Rotation) MP 8. Not Adjustable 1-8-4-3-6-5-7-2 (LH Rotation) MP 6.MR43LTS 0.7L (330 HP) AC .060 in.1L(STD) (385 HP) MP 8.0L (370 HP) NGK .0L (275 HP) MP 5.060 in.

3. such as STA-BIL™. added to any fuel remaining in the tanks. Flush the cooling system if operating in salt water or brackish water areas. Fill the fuel tanks with gasoline (that does not contain alcohol) and add a sufficient amount of gasoline stabilizer. 4. the engine fuel system must be run dry at idle RPM. into the throttle body assembly bores. Be sure the engine compartment is well-ventilated to prevent a potential fire hazard. during storage. Cover the throttle body assembly. Shut down the engine and change the oil and oil filter (See ENGINE MAINTENANCE). CAUTION Refer to FLUSHING COOLING SYSTEM before proceeding. Remove the flame arrestor and start the engine. 1. Clean the flame arrestor and the vent hoses. Turn the ignition switch to the OFF position. to treat internal surfaces of the engine. Run the engine and allow it to reach normal operating temperature. 5. 54 . refer to draining and refilling procedures. and reinstall on the engine.13 ENGINE STORAGE IMPORTANT: This service should be performed by an Authorized PCM Dealer. to prevent the formation of fuel gum and varnish. Close the fuel shut-off valve (if equipped). Follow the instructions on the container. Fuel tanks should be drained completely and fuel conditioner. IMPORTANT: If the boat is to be place into storage with fuel containing alcohol in the fuel tanks. 6. The fresh-water cooling system must be serviced before fogging the engine for storage. such as STA-BIL™ fuel stabilizer. Refer to the instructions on the fogging solution canister. NOTICE: If the engine is equipped with the optional fresh-water cooling system. Operate the engine at a fast idle speed (1000-1500 RPM). Use an aerosol-type fogging solution and spray sufficient amount. (See ENGINE MAINTENANCE).OUT-OF-SEASON STORAGE . to prevent the possibility of the water entering the engine through the throttle body assembly. WARNING Operate the bilge blower and be sure no fuel vapors are present when treating the engine. 2.

Pour the mixture of antifreeze and water. 7. IMPORTANT: When removing the drain plugs. properly mixed to protect the engine to the lowest temperatures that it will be exposed to. Remove the large hose from the engine circulating pump. Remove all the drain plugs from the following locations: • Cylinder Block .0/5. Exhaust Manifolds . It may be necessary to drain the system prior to re-commissioning the boat. perform the additional required maintenance as outlined in the MAINTENANCE SCHEDULE under ONCE EACH YEAR.0/5.OUT-OF-SEASON STORAGE . NOTICE: It may be necessary to bend or lift the hoses to allow water to drain completely. coat the threads of the drain plugs with PerfectSeal (or equivalent).remove hoses and/or drain plugs. allowing sea water to flow from drain holes or removed hoses. insert a wire into the hole to remove any obstruction which would prevent water from draining completely. After draining is completed.0/5. and reinstall in the proper locations. DO NOT allow the engine to start.one on each side (5. remove the knock sensor on the port side). check with local environmental agencies about the proper disposal of antifreeze. 6. Remove the hose from the inlet side of the seawater pump. Remove the large circulating pump hose from the thermostat housing. 8. one on each side Transmission and Engine Cooler . Remove the hoses which connect to the exhaust manifolds from the thermostat housing. Crank the engine over once to purge any trapped water in the sea-water pump.one drain plug Remove large HOSE. 3. or DRAIN PLUG (if equipped) Figure 13-1 Draining Engine Circulating Pump (5. into the circulating pump hose and fill the engine block. 4. When installing the knock sensor.m (15 lb ft). Reinstall the hoses into the thermostat housing and tighten the hose clamps securely. you may wish to fill the engine with antifreeze. torque to 20 N. 5. Reinstall all the hoses and tighten the Figure 13-2 Draining Engine Circulating Pump (5. If ethylene glycol based antifreeze is used.13 DRAINING INSTRUCTIONS CAUTION If the boat is to remain in the water during or after draining.7L) NOTICE: For additional protection against freezing and corrosion. After the water has completely drained.7L engines. close the seacock to prevent a siphoning action that may occur. Pour additional antifreeze solution into the hoses connected to the exhaust manifolds.7L) • • 2. LARGE HOSE DRAIN LOCATION RAW-WATER COOLED MODELS 1. or drain plug (if equipped). 55 .

check the water level and recharge the battery to the manufacturer’s specifications.OUT-OF-SEASON STORAGE . one on each side Engine Cooler . coat the threads of drain plugs with PerfectSeal. Remove all the drain plugs from the following locations: • • Heat Exchanger . use the following instructions: • Remove the battery from the boat and clean. If not available. IMPORTANT: Drain sea-water section of the cooling system only.remove hoses and/or drain plugs. perform the additional required maintenance as outlined in the MAINTENANCE SCHEDULE under ONCE EACH YEAR. 3. Do not fast charge. DO NOT allow the engine to start.13 FRESH-WATER COOLED MODELS IMPORTANT: The fresh-water section of the cooling system must be kept filled year around with recommended coolant. • 4.one on outboard side Exhaust Manifolds .one drain plug • 2. See DRAINING FRESH-WATER COOLING SYSTEM in ENGINE MAINTENANCE section for draining and refilling procedures of FWC system. 56 . After the water has completely drained. removing dirt and grease from the top of the battery. Do not store on a concrete surface. Periodically (every 30 to 45 days). Store the battery in a cool. dry place. Reinstall the hoses and tighten all the clamps securely. Remove the hose from the inlet side of the seawater pump. Crank the engine over once to purge any trapped water in the sea-water pump. 1. and reinstall in the proper locations. BATTERY STORAGE Follow the battery manufacturer’s instructions for storage. • • CAUTION A discharged battery can be damaged by freezing. After draining is completed. or (equivalent). if required. Fill the battery with distilled water to the manufacturer’s specifications. 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.

Allow the engine to reach normal operating temperature. the electrical system will be damaged. and the NEGATIVE (-) BATTERY CABLE to the NEGATIVE (-) BATTERY TERMINAL last. If the battery cables are reversed. WARNING Do not use jumper cables and/or a booster battery to start the engine. Check the steering. exhaust. Be sure they are properly connected and all the hose clamps are tight. Be sure that all the connections are clean and free from corrosion. oil and water leaks. use the procedure FLUSHING COOLING SYSTEM before proceeding to start the engine(s). Start the engine and closely observe the instrument panel. the following items should be checked: • Check all the cooling system hoses.OUT-OF-SEASON STORAGE . • • Open the seacock before starting the engine. • Install the fully charged battery.13 FITTING OUT AFTER STORAGE When recommissioning the engine after storage. Do not recharge a weak battery in the boat. CAUTION If the engine(s) is to be started prior to launching. make certain that you connect the POSITIVE (+) BATTERY CABLE to the POSITIVE (+) BATTERY TERMINAL first. • 57 . sparks or open flame. • CAUTION When installing the battery. Remove the battery and recharge in a ventilated area away from fuel vapors. Refer to the OPERATING INSTRUCTIONS section and perform all the safety checks before starting the engine. Inspect the engine carefully for fuel. shift and throttle controls for proper operation. Coat the battery terminal connections with an anti-corrosion battery terminal spray.

Improper starting procedure. consult a PCM Engines Servicing Dealer for assistance. Plugged fuel filters. Dead Battery Engine Cranks .will not start or is hard starting. immediately return the throttle to 1000 RPM. Faulty fuel pump .TROUBLESHOOTING . Position the remote control exactly in Neutral. Turn the battery switch ON. If contaminated. No fuel . Refer to “STARTING ENGINE” in the OPERATING INSTRUCTIONS section. Replace the fuse . Corrective Action Contact PCM Engines Dealer. NOTICE: Battery voltage must be AT or ABOVE 10 volts while the engine is cranking or the engine management system will not function. drain and clean the fuel system. Check the fuel tank level . Clean and tighten all connections.14 Engine performance complaints usually fall under one of the basic headings listed in the Troubleshooting Guide. Malfunction Engine will not crank with the starter motor. Faulty anti-siphon valve. Battery switch turned OFF (if equipped) Remote control not in Neutral position. Check the battery cables and starter circuit wiring.reset circuit breakers. When a problem cannot be easily diagnosed. Open the throttle 100% and crank the engine. Repair or replace the damaged wiring. Open shut-off valve(s).check electrical connections.empty fuel tank No fuel to the throttle body (TBI) or the injectors (MPI) Engine flooded Ignition system malfunction Contaminated fuel 58 . Blown the ignition fuse or open circuit breakers. or cranks slowly. When the engine starts. Check fuel for water or other contamination. Possible Cause Problem with the engine management system. Loose and/or dirty wiring connections.fill tank(s). NOTICE: Battery voltage must be AT or ABOVE 10 volts while the engine is cranking or the engine management system will not function. Recharge. Contact PCM Engines Dealer. Plugged or kinked fuel lines or plugged fuel-tank vent. test and replace as necessary.

(insufficient engine temperature.) Crankcase overfilled causing oil aeration Diluted or improper grade/ viscosity of oil 59 . Change the oil and filter. Determine the cause of dilution. Faulty thermostat Sea-water intake valve partially/fully closed. Restricted sea-water pickup Faulty temperature sending unit or gauge Sea-water pump impeller worn or damaged The following applies to engines equipped with Fresh-Water Cooling (FWC) systems. Replace the temperature sender.50% water). Replace the impeller. Test and replace as necessary. Coolant level low in the fresh-water section of the cooling system Remove restriction. Check the cooling system for leaks. etc. Clean and flush the exchanger. Remove the required amount of oil. Transmission/engine oil cooler plugged Remove the water hoses and flush in opposite direction of the normal flow. excessive idling. etc. Open the valve completely.). kinked or leaking hoses. Refill the system. Replace the hoses. Replace the thermostat. Insufficient engine temperature Faulty thermostat Faulty temperature sender Engine oil pressure low Faulty oil pressure sending unit or gauge Oil level low Add specified oil. Check the engine for leaks.14 Malfunction Engine Overheats Possible Cause Loose or worn drive belt(s) Corrective Action Adjust or replace the belts as necessary. See Warning before removing the fill cap. Collapsed. Determine the cause of overfilled condition (improper filling.TROUBLESHOOTING . Test and replace as necessary. Heat exchanger passages plugged with scales and debris Improper coolant mixture Install the proper coolant mixture (50% antifreeze . Replace the thermostat.

Plugged or kinked fuel lines or fuel tank vent Anti-siphon valve faulty Flame arrestor dirty Poor engine or boat performance Ignition malfunction Throttle not fully open Damaged or improper propeller Excessive water in the bilge Excessive growth on the boat bottom Boat overloaded Dirty flame arrestor Engine overheating 60 . Clean the flame arrestor. Clean the flame arrestor. Clean the bottom and paint with an anti-fouling paint. Remove obstruction. Check the shift cables for freedom of movement and binding. Reduce and/or redistribute the load. Check the remote control and throttle body linkage for freedom of movement and proper adjustment. Repair or replace as necessary.TROUBLESHOOTING . Replace the fuel filters. Repair the cooling system (See “Engine Overheats”). Drain required amount of oil. Transmission overfilled causing oil aeration Transmission shift lever not fully engaged Adjust the shift linkage and remote control. Clean or replace as necessary. Contact PCM Engines Dealer.14 Malfunction Transmission slipping erratic operation Possible Cause Low oil level Corrective Action Add specified oil. Contaminated fluid Engine misses. Pump the water out and investigate source of entry. Have fuel pump replaced by a PCM Engines Dealer/ Repair or replace the fuel lines. Check the transmission for leaks. Determine and correct the contamination source and change the fluid. runs rough and/or backfires Ignition system malfunction Plugged fuel filters Faulty fuel pump. Contact PCM Engines Dealer.

14 This Page Was Intentionally Left Blank 61 .TROUBLESHOOTING .

7L Belt-Driven Raw Water Pump) 62 = Drain Locations .0/5.WATER FLOW DIAGRAMS .m (15 lb ft) = RAW WATER FLOW Figure 15-1 Raw-Water Cooling System (5.15 Knock Sensor Torque 20 N.

From Intake Manifold To Cylinder Block Figure 15-2 Fresh-Water Cooling System (5.7L) To Cylinder Block = RAW WATER FLOW = FRESH WATER FLOW WATER FLOW DIAGRAMS .15 63 = Drain Locations .0/5.

e. heater. heaters.WATER FLOW DIAGRAMS .e. Figure 15-3 Fresh-Water Cooling System (6.0L) 64 .Water RETURN from heater or hot water tank NOTE: Location A is the cooling system bypass. This bypass hose MUST NOT be tampered with. DO NOT hook up any external accessories (i. HOSE 1 . hot water tank) Hook Up A tee may be inserted anywhere in the specified hose for most appropriate routing.15 1 1 2 1 2 1 2 2 2 2 A 2 = RAW WATER FLOW = FRESH WATER FLOW = Drain Locations IMPORTANT: Accessory (i. hot water tanks) at this location.Water OUT to heater or hot water tank HOSE 2 .

WATER FLOW DIAGRAMS .15 = RAW WATER FLOW Figure 15-4 Raw-Water Cooling System (8.1L) 65 = Drain Locations .

1L) = RAW WATER FLOW = FRESH WATER FLOW = Drain Locations .15 66 To Engine Block To Engine Block Figure 15-5 Fresh-Water Cooling System (8.WATER FLOW DIAGRAMS .

9. NOTE A : POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM THIS LOCATION. 6. 8. 7. 10. 3. A Figure 16-1 Typical Instrumentation Wiring 67 . 4. 2. CIRCUIT NAME GROUND TACHOMETER WATER TEMPERATURE ENGINE ALARM IGNITION BATTERY STARTER OIL PRESSURE CHECK ENGINE LIGHT DATA LINE ENGINE HARNESS WIRE COLOR BLACK GRAY TAN TAN/BLACK PURPLE/WHITE RED/WHITE YELLOW/RED LT.16 ENGINE HARNESS WIRE HARNESS COLOR CHART CIRCUIT NUMBER 1. 5.INSTRUMENTATION WIRING DIAGRAMS . LOAD CANNOT EXCEED 30 AMPS. BLUE BROWN/WHITE ORANGE/BLACK 2 10 3 4 1 8 9 7 6 5 NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.

LITERATURE .17 To obtain service and/or parts literature for your PCM Marine Engine. PARTS: Parts manuals with exploded views for service parts are available for all current engine models. 2. 68 . This manual contains complete engine and component disassembly and reassembly instructions. be sure to include your engine model and serial number to insure the service information you receive is correct. IMPORTANT: When contacting the factory for service information. PCM has a detailed service manual available. SC 29075 1. contact the following: PCM Engines Pleasurecraft Engine Group Publications Department 1737 Highway 76 East Little Mountain. Troubleshooting and maintenance charts are also included. SERVICE: For more detailed information.

reflecting the change has been made in the factory computer.STATE. provided the engine does not have in excess of 300 hours. S.18 PCM WARRANTY TRANSFER APPLICATION The remainder of the original PCM limited warranty is transferable within thirty (30) days of date of sale by the original owner/user to a subsequent purchaser for the remainder of the unused portion of the original warranty term. AND CANADA. ________________________________ (Technician Signature. All terms in the Limited Warranty located in the Engine Owners Manual still apply.. PRE-DELIVERY POINTS CHECKLIST (TECHNICIAN TO CHECK ALL POINTS AND SIGN BELOW) ___ ENGINE OIL ___CONTROL ADJUSTMENTS ___ALTERNATOR CHARGE ___CHECK LUBE POINTS ___SHAFT ALIGNMENT ___EXHAUST HOSES/CLAMPS ___TIGHTEN WATER LINES ___BELT TENSION ___TIMING ___BATTERY CHARGE AND LEVEL ___TIGHTEN DRAIN PLUGS ___PROP SIZE & ROTATION ___DRIVE LUBE ___CONTROL TRAVEL ___SET IDLE SPEED ___CHECK FOR LEAKS ENGINE MODEL:_______________________________ TRANS.FORMS . The original date of sale or original in-service date (whichever comes first) begins the warranty coverage period. OUTSIDE THE U. ZIP___________________________________________________________________________________________ I hereby certify the pre-delivery checklist on engine #___________ and have corrected any abnormality revealed by this inspection. SERIAL:_______________________________ ENGINE SERIAL:___________________________________________ ENGINE HOURS:___________________________________________ DATE OF SALE (2ND Owner) ______/______/______ DATE OF SALE (1st Owner/1st Operator) ______/______/______ (New Owner) NAME:__________________________________________________________________________________________________________________ ADDRESS:______________________________________________________________________________________________________________ CITY. Original owner’s plastic Warranty Registration Card Copy of Bill of Sale/Sales Contract/Operator Contract Completed Warranty Transfer Application Warranty transfer fee IMPORTANT! PURCHASER NOTICE: The checks listed below are designed to insure safety and satisfaction.S.STATE.00.O. 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: Transfer Fee: • The fee for transfer is $100. ZIP___________________________________________________________________________________________ (Previous Owner) NAME:__________________________________________________________________________________________________________________ ADDRESS:______________________________________________________________________________________________________________ CITY. Dealer & Date) ____________________________________ (Seller’s Signature & Date) ____________________________ (Purchaser’s Signature & Date) 69 . The applicable transfer fee must be submitted via certified check within 30 days of date of sale along with the transfer application information to: Pleasurecraft Engine Group P. CONTACT YOUR LOCAL PLEASURECRAFT DEALER OR WARRANTY SERVICES AT (803) 345-0050 FOR MORE INFORMATION ON HOW TO APPLY TO THIS PROGRAM. Therefore. By signature the technician certifies that he/she has checked the installation and operation of the engine and finds it to be performing properly.C. Drawer 369 Little Mountain. we require the following inspection be performed at your expense by a qualified technician prior to delivery. 29075 • A Warranty Registration Card will be issued to the second owner.

PO Drawer 369. Note: * 1997 model year engine in a Correct Craft vessel offered 3 Year Warranty on GM engines * 1997 PCM and later model year engines offered transferable warranty. 200 hours. SC 29075. GM engine. unlimited hours Transmission. (Does not apply to any earlier model) ** Special 25th Anniversary Edition PCM Ford GT-40 engines. unlimited hours Transmission 1 year. 200 hours. 3 years. 200 hours. Ford and GM.STATE. 3 years. 200 hours with exclusions.ZIP: ________________________________________________________________________________ DATE OF PURCHASE: ___________________________________________________________________________ (Previous Owner)NAME: _________________________________________________________________________ ADDRESS: _____________________________________________________________________________________ CITY. This list has been compiled only as a general outline of year and hour limits imposed on different models of PCM engines.. 3 years. Recalls. 3 years. 2 years. 2 years. in any way. etc. unlimited hours. Engine and Transmission 3 years. 3 years. 200 hours Transmission. 200 hours.18 PCM SUMMARY OF WARRANTY TERM LIMITS This list does not.1996 1997* . 2 years. 2 years.1999 2000 2001** 2002 ** 2003 Base Engine WARRANTY COVERAGE TERM: 1 year.ZIP: ________________________________________________________________________________ 70 . complete the section below and return by mail to PCM. GM. 3 years. 200 hours. 3 years. Please review the official Limited Warranty Statements on the following pages for specific terms and limitations as they apply to the particular engine / component involved. Ford engine.STATE. Ford and GM. modify the official Limited Warranty Statement of PCM. unlimited hours Transmission 3 years. Ford and GM. Little Mountain. unlimited hours. unlimited hours Transmission.FORMS . 2 years. unlimited hours. unlimited hours. ENGINE MODEL: ENGINE SERIAL NUMBER: GEAR MODEL: GEAR SERIAL NUMBER: _________________________ _________________________ _________________________ _________________________ (New Owner) NAME: _____________________________________________________________________________ ADDRESS:______________________________________________________________________________________________________________ CITY. unlimited hours. Engine and Transmission. ENGINE MODEL YEAR: 1992 & OLDER 1993 1994 . unlimited hours Transmission 3 years. 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 notification purposes in case of Service Updates. Ford and GM. Transmission. have a fourth year of product protection on all internal engine components supplied by Ford Power Products.

Ignition Key Number Port Stbd. Fire Extinguisher Checked Batteries Tested Runs Made Date Gal of Fuel Qts of Oil Port Stbd. Drive Serial # Port Stbd.FORMS . Miles Hours Oil Change Check Drive Lay Up Date Launch Date Remarks 71 .18 OPERATION AND MAINTENANCE LOG Engine Model and Serial # Port Stbd.

mail this form to: Pleasurecraft Marine PO Box 369 Little Mountain.18 PROBLEM NOTIFICATION OR INFORMATION REQUEST FORM IMPORTANT: All blanks MUST be completed to insure proper identification of your engine which is necessary to properly understand your request.FORMS . I would like to inform you of a problem I have experienced with the above engine. When completed. My problem is: My boat is located at Address City Requestors Signature Telephone ( State ) Zip Date 72 . SC 29075 Gear Serial Number Engine Model Engine Serial Number Owner Information Name Address City Selling Dealer Dealers Address Date of Purchase Boat Make Telephone ( State ) Zip Length Type Gentlemen.

NOTES .19 73 .

19 74 .NOTES .

19 75 .NOTES .

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