OWNER’S OPERATION

and

MAINTENANCE MANUAL

A Division of
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Thank you for your selection of Pleasurecraft (PCM) Marine Power for your boating needs. We welcome you to Team
PCM, which puts you in the company of tens of thousands of boaters who have relied on Pleasurecraft inboards as their
power of choice for over 30 years.

When you chose PCM, you selected the utmost in premium power for your boating application. Pleasurecraft is the
world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting edge technology. Over
the years, we have introduced many breakthrough innovations that quickly became industry standards. The pyramidal
exhaust system, light-weight transmission, computerized engine control and the Fuel Control Cell (FCC) are all PCM
innovations. No matter which PCM model you purchased, you can be sure it is equipped with the latest in modern
technology for added performance and durability.

READ THIS MANUAL THOROUGHLY

Before starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand any
portion of the manual, contact your Dealer for clari cation or assistance. Ask your Dealer for a demonstration of actual
starting and operating procedures.

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

This manual will cover the following year of manufacture PCM engines:

Year Model

2009 5.0L MPI

2009 5.7L MPI - EX 343

2009 6.0L MPI - ZR409

*2009 Catanium™ CES ProSport 5.0L

*2009 Catanium™ CES 5.7L EX-343

*2009 Catanium™ CES 6.0L ZR-409

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

Part Number - L510010-09 Printed 06/09

 PROPOSITION 65

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

Part Number - L510010-09 Printed 06/09

 TABLE OF CONTENTS
INTRODUCTION ............................................................................................................................... 3-5
Registration Information (Warranty Registration Card is located at the back of this manual) ........................ 3
3-Year Transferable Limited Warranty ..................................................................................................... 4
California Emission Control Warranty Statement ..................................................................................... 5
PCM Inboard Marine Engine Manufactured after 2008 General Emissions Warranty Coverage ................... 6
Safety Information ................................................................................................................................ 9
Replacement Parts ............................................................................................................................... 9
Safety Warnings ................................................................................................................................... 9
BOATING RESPONSIBILITY ......................................................................................................... 10-12
Carbon Monoxide Hazard .................................................................................................................... 10
Safe Boating Suggestions ................................................................................................................... 11
Water Wisdom .................................................................................................................................... 11
Operation and Maintenance ................................................................................................................. 11
Rules of the Road ............................................................................................................................... 12
ENGINE IDENTIFICATION ............................................................................................................. 13-14
Engine Identification ............................................................................................................................ 13
Owner Identification and Registration Information .................................................................................. 13
Engine Model Identification / Advisory ................................................................................................... 14
ELECTRONIC FUEL INJECTION INFORMATION ................................................................................ 15
Electronic Fuel Injection System .......................................................................................................... 15
OPERATING INSTRUCTIONS ........................................................................................................ 16-20
Engine Alarm System .......................................................................................................................... 16
Instrumentation ................................................................................................................................... 17
Electronic Speed Control ..................................................................................................................... 17
Starting Engine (Fuel Injected Engines) ................................................................................................ 17
Shifting Transmission .......................................................................................................................... 19
Stopping Engine ................................................................................................................................. 20
Freezing Temperature Operation .......................................................................................................... 20
Operation in High Debris Areas ............................................................................................................ 20
PCM Basic Cruise Speed Control System ........................................................................................ 21-22
CONDITIONS AFFECTING OPERATION ........................................................................................ 23-24
Trim and Weight Distribution ................................................................................................................ 23
Boat Bottom ....................................................................................................................................... 23
Propeller Selection .............................................................................................................................. 24
ENGINE BREAK-IN PERIOD .............................................................................................................. 25
25-HOUR ENGINE INSPECTION ........................................................................................................ 26
FUEL REQUIREMENTS ..................................................................................................................... 27
Gasoline Requirements ....................................................................................................................... 27
Gasoline Containing Alcohol ................................................................................................................ 27
OIL REQUIREMENTS ........................................................................................................................ 28
Engine Oil Recommendations .............................................................................................................. 28
Transmission and “V”-Drive Oil Requirements ....................................................................................... 28
ENGINE MAINTENANCE ............................................................................................................... 29-55
Engine Maintenance ........................................................................................................................... 29
Checking Fluid Levels .................................................................................................................... 29-31
Lubrication ......................................................................................................................................... 31

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TABLE OF CONTENTS
Electrical System Relay and Fuse Block ............................................................................................... 32
Electrical System Fuses ............................................................................................................. 32
Boat’s Ignition Fuse ................................................................................................................... 32
Electrical System Wiring and Connectors ...................................................................................... 32
Battery .................................................................................................................................... 33
Fresh Water Cooling System Sacrificial Zinc Anode ......................................................................... 34
Checking Coolant Level ............................................................................................................. 35
Flushing Cooling System - Sea-Water Section ................................................................................ 36
Testing Coolant For Alkalinity ...................................................................................................... 37
Draining Fresh-Water Cooling System .......................................................................................... 37
Filling Fresh-Water Cooling System .............................................................................................. 38
Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) ....................... 39
Fuel System Description ............................................................................................................ 40
Fuel Control Cell (FCC) Fuel System ............................................................................................ 40
Servicing the FCC ..................................................................................................................... 41
Primary Fuel Filter (FCC Clamp-on Canister) ............................................................................. 41-42
Servicing Fuel Pre-Filter ............................................................................................................. 43
Priming Fuel System ................................................................................................................. 43
Flame Arrestor ......................................................................................................................... 43
Accessory Drive Belt ............................................................................................................. 44-45
Servicing Raw Water Pump Impeller ........................................................................................ 44-45
Changing Oils .......................................................................................................................... 46
Engine Alignment ................................................................................................................. 47-50
Engine Maintenance Log ............................................................................................................ 51
Maintenance Schedule .......................................................................................................... 52-53
Visual Inspection ...................................................................................................................... 54
Engine Fluid Capacities ............................................................................................................. 54
Transmission Fluid Capacities ..................................................................................................... 54
Filter and Accessory Requirements .............................................................................................. 55
ENGINE SPECIFICATIONS ................................................................................................... 56-58
OUT-OF-SEASON STORAGE ................................................................................................ 59-62
Engine Storage ........................................................................................................................ 59
Draining Instructions .................................................................................................................. 60
Battery Storage ........................................................................................................................ 61
Recommissioning After Storage ................................................................................................... 62
TROUBLESHOOTING .......................................................................................................... 63-65
RAW WATER FLOW DIAGRAMS ........................................................................................... 66-75
HEATER CONNECTIONS ..................................................................................................... 76-77
INSTRUMENTATION WIRING DIAGRAM ..................................................................................... 78
LITERATURE .......................................................................................................................... 79
FORMS............................................................................................................................... 80-83
NOTES ................................................................................................................................... 85
WARRANTY/REGISTRATION CARD .

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 INTRODUCTION - 1
REGISTRATION INFORMATION
(Warranty Registration Card is located at the
back of this manual)

Shortly after your purchase is registered with PCM, you

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

Again, thanks for choosing PCM. We sincerely wish you

happy days on the water.

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INTRODUCTION - 1
3 Year Transferable Limited Warranty
Pleasurecraft Marine Engine Co. (PCM) warrants its new products to be free from defects in material and workmanship under normal use and service
conditions, to the first registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty
coverage within 30 days of any subsequent sale/purchases. All components of PCM products are covered under the PCM Warranty, except for those components
that are warranted by PCM’s suppliers. The obligation of PCM hereunder shall be limited to the repair or replacement with new or remanufactured components, at
its option, of any product or parts thereof which has failed during the period of warranty and which is demonstrated upon examination to have failed due to defective
material and/or workmanship.
PCM’s policy is one of continued improvement of its products and PCM hereby reserves the right to improve and change the design and production of any
of its products without assuming any obligation to modify products previously manufactured and/or sold.

NO OTHER WARRANTY GIVEN

The obligations set forth in the preceding paragraph are PCM’s sole obligation and owner’s exclusive remedy. PCM makes no other express
warranty to the extent that any additional warranty may be implied by law, the term of such implied warranty shall be limited to the warranty term stated herein,
from the date of delivery of the PCM product to the parties outlined herein.
No distributor, dealer, agent or employee of PCM is authorized to grant any other or further warranty or incur any additional warranty obligation on PCM’s
behalf, in connection with the sale of its products. Any qualification or restriction contained herein which is prohibited by any law of mandatory application shall be deemed
to be deleted herefrom, however, such deletion shall have no effect on the remaining provisions hereof, all of which shall remaining full force and effect.

REMEDIES
The obligations of PCM set forth in the first paragraph of this Warranty shall be the exclusive remedy for any breach of Warranty hereunder, and any owner
or user’s sole remedy in the event of breach of the warranties which are made by PCM is repair or replacement of the product or any warranted part thereof as set forth
herein: with this sole exception, PCM shall not be liable for any direct, or indirect, incidental or consequential damages, including without limitation, any damages
for property damage, loss of use or loss of profits, loss of income, inconvenience, trailering, towing, haul out, launch and/or any other in and out of water expenses, storage
charges, dockage charges, expenses to deliver or pick up the product being warranted to and from the dealer, telephone expenses, lodging expenses, travel expenses,
mechanic travel time and mileage, damage caused by any occurrence of an insurable nature, rental of substitute equipment of any type, removal and replacement and/or
modification of any boat parts to facilitate repairs, moving of furniture, carpets, cleaning, painting, carpenter work, or re-delivery charges.
Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.
Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may
not apply to you.
Any owner or user hereby waives for himself/herself/itself and his/her/its successor and assigns (a) any and all claims for punitive damages,
and (b) all claims of negligence or strict liability or both, In no event will PCM’s liability exceed the purchase price of the goods which is actually paid to PCM.

WARRANTY COVERAGE, TERM

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

OBTAINING PERFORMANCE UNDER WARRANTY

PCM’s warranty registration form should be prepared by your selling dealer, executed by you and the dealer and mailed, by you, to PCM within 30 days
after the date of purchase. Upon receipt of the warranty registration form, PCM will issue to you a personalized owner’s registration card which will be mailed directly to
you. If the owner’s registration card is not received within eight (8) weeks after the date of purchase, please write PCM at the address below.
At the time that a claim for warranty service is made, the owner’s registration card should be presented to the person or entity providing warranty service.
Authorized PCM dealers or distributors are entitled to be reimbursed by PCM for some or all of the expense of warranty repairs, thus, service under the terms of this
Warranty will be performed by an authorized PCM dealer or distributor without charge for established flat rate labor or replacement parts, other than items not covered by
the Warranty, such as , but not limited to, lubricants, spark plugs, points, and other items which are normally frequently replaced as part of routine maintenance. Charges
for additional non-warranty work and/or additional dealer charges for labor relative to warranty work in excess of flat rate must be paid for by the owner.
Prior authorization in writing must be obtained from PCM for any warranty repairs over $50.00 and in all cases where the owner fails to establish the
purchase and warranty expiration dates with the owner’s registration card sent upon receipt of the warranty registration form by PCM. While failure to present the
owner’s registration card will not prevent you from obtaining coverage hereunder, this Warranty shall not be effective and, therefore, cannot be honored until the product
purchase date can be confirmed by PCM. If the card is lost, communicate with PCM at the address listed below, and, for a processing fee of $10.00, a new owner’s
registration card will be issued to you.
Any questions concerning service, parts or this Warranty should be directed to your selling dealer. If your dealer is unable to assist or if you relocate or are
travelling or need a referral to your nearest dealer contact: Pleasurecraft, P.O. Drawer 369, Little Mountain, SC 29075

FAILURES EXCLUDED FROM WARRANTY

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

OWNER’S RESPONSIBILITY
Performance under this Warranty shall be conditioned upon the 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, all requested information recorded and that the selling dealer has
signed the warranty registration.
2 Owner or user shall promptly mail the warranty registration to PCM after accepting delivery.
3 Owner or user shall follow the instruction in the owner’s manual regarding operation, break-in, lubrication, and fuel.
4 Owner or user shall follow or comply with the maintenance schedule, operation limits, and lay up instruction, as outlined in the owner’s manual.

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

SPECIAL STATE LEGAL REQUIREMENTS

This Warranty gives you specific legal rights, and you may also have other rights which vary from State to State.
The PCM California Emissions Warranty and California Emissions Control Warranty Statement is a separate document included in this Manual. Any
questions concerning the Emissions Warranty can be obtained by calling 1-803-345-0050.
 INTRODUCTION - 1
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Pleasurecraft Marine Engine Co. (hereinafter “Pleasurecraft”) are
pleased to explain the emission control system warranty on your inboard marine engine manufactured
after January 1, 2008. In California, new inboard engines must be designed, built and equipped to meet
the State’s stringent anti-smog standards. Pleasurecraft must warrant the emission control system on your
inboard engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your inboard engine.

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

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

MANUFACTURER’S WARRANTY COVERAGE:

Select emission control parts from inboard marine engines manufactured after January 1, 2008 are
warranted for 3 years or 480 hours, whichever first occurs.

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

OWNER’S WARRANTY RESPONSIBILITIES:

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

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

– You are responsible for presenting your inboard engine to an authorized Pleasurecraft dealer as soon as
a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30
days.

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

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INTRODUCTION - 1
PLEASURECRAFT MARINE ENGINE CO. GENERAL EMISSIONS WARRANTY
COVERAGE (Engines Manufactured after January 1, 2008)

1. Pleasurecraft Marine Engine Co. (hereinafter referred to as “Pleasurecraft”) warrants to the first owner
purchasing at retail, and all subsequent owners, of every Pleasurecraft inboard marine engine manufactured
after January 1, 2008, that the emissions control devices on Pleasurecraft inboard marine engines are free
from defects in materials and workmanship when manufactured and will remain so for a period of three
(3) years or 480 hours, whichever first occurs, from the date of delivery to the first owner purchasing
the engine at retail or from the date the engine is first placed into service for demonstration or any other
purpose prior to sale to the first owner purchasing the engine at retail.

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

3. Any part covered under this Warranty that is not scheduled for replacement as required maintenance, in
the written instructions to be found within the Pleasurecraft Owners/Operators Manual, is warranted for the
period of three (3) years or 480 hours, whichever first occurs. If the part fails during the period of warranty
coverage, Pleasurecraft will repair or replace the defective part at any Pleasurecraft warranty station. The
repair or replacement will be performed at no charge to the owner. Any such part repaired or replaced
under this Warranty will be warranted for the remainder of the three (3) year or 480 hours, whichever first
occurs, period.

4. Any part covered under this Warranty that is scheduled only for regular inspection in the written instructions
to be found within the Pleasurecraft Owners/Operators Manual, is warranted for the period of three (3) years
or 480 hours, whichever first occurs. If the part fails during the period of warranty coverage, Pleasurecraft
will repair or replace the defective part at any Pleasurecraft warranty station. The repair or replacement
will be performed at no charge to the owner. Any such part repaired or replaced under this Warranty will
be warranted for the remainder of the three (3) year or 480 hours, whichever first occurs, period.

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

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

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

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 INTRODUCTION - 1
8. To insure prompt repair under this Warranty, Pleasurecraft will maintain a supply of warranted parts sufficient
to meet the expected demand for such parts. Any replacement part may be used in the performance of any
warranty maintenance or repairs and will be provided by Pleasurecraft without charge to the owner.

9. Parts covered under this Warranty are:

1. Fuel Metering System 4. Lubrication System

A. Fuel Injectors A. Oil Pump and Internal Parts
B. Fuel Pressure Regulator 5. Positive Crankcase Ventilation (PVC) System
C. Manifold Absolute Pressure Sensor A. PCV Valve
D. Throttle Position Sensor B. Oil Filler Cap
E. Throttle Body - Port Fuel Injection Models 6. Exhaust System
F. Coolant Temperature Sensor A. Exhaust Manifold(s)
G. Intake Valves B. Exhaust Riser(s)
H. Oxygen Sensors C. Exhaust Valves
2. Air Induction System D. Catalytic Converters
A. Intake Manifold 7. Miscellaneous Items Used on Above Systems
B. Air Filter (Flame Arrestor) A. Hoses, clamps, fittings, tubing, sealing
gaskets or devices and mounting hardware
3. Ignition System B. Electronic Controls
A. Spark Plugs C. Electronic Control Module
B. Electronic Ignition System D. Pulleys, belts and idlers
C. Ignition Coil and/or Control Module
D. Ignition Wires

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

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

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

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INTRODUCTION - 1

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 INTRODUCTION - 1
SAFETY INFORMATION REPLACEMENT PARTS

“Safety Warnings” and additional information or DANGER

instructions are used to alert the installer/operator of
possible safety hazards in performing certain service
Electrical, ignition and fuel system components are
or maintenance procedures incorrectly or carelessly.
designed and manufactured to comply with U.S.
DANGERS and WARNINGS are accompanied by the
Coast Guard rules and regulations to minimize the
international HAZARD symbol:
possibility of fire or explosion hazard.
These “Safety Warnings” alone cannot eliminate the
hazards that they signal. Strict compliance with Use of replacement parts (i.e. automotive, after-market,
these warning instructions while performing service etc.) in the electrical, ignition and fuel systems, which are
and maintenance procedures, plus “common sense” not U.S. Coast Guard approved, could cause a fire or
operation, are major accident prevention measures. explosion hazard and should be avoided.

Always request that genuine PCM Engines replacement

parts be used in any repairs or maintenance being
performed on your engine(s).

SAFETY WARNINGS

DANGER

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

WARNING

Indicates a potential hazard which could result in personal injury.

CAUTION

Indicates a hazard which could result in damage to equipment.

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

WARRANTY NOTICE: Indicates a possible warranty exclusion.

L510010-09
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BOATING RESPONSIBILITIES - 2
CARBON MONOXIDE HAZARD To find out more about making boating safer, including
how you can prevent carbon monoxide poisoning on
recreational boats, contact:
DANGER
National Marine Manufacturers Association
Carbon Monoxide (CO) is a colorless, odorless
200 East Randolph Drive
and tasteless gas. You cannot see it, smell it or
Suite 5100
taste it. Prolonged exposure to carbon monoxide
Chicago, IL 60601-6528
can lead to unconsciousness, brain damage or
www.nmma.org
death!
312-946-6200
Carbon monoxide is produced when anything that
contains carbon, such as gasoline, natural gas, oil, United States Coast Guard
propane, coal or wood is burned. Carbon monoxide is Office of Boating Safety
commonly found in the exhaust of internal combustion CG Headquarters G-OPB-3
engines (boat power plants, generators, etc.). In 2100 Second Street SW
addition, open flame devices like cooking ranges, Washington, DC 20593
heaters and charcoal grills also produce carbon www.uscgboating.org
monoxide. 202-267-0984

Carbon monoxide accumulation, in and around boats American Boat & Yacht Council, Inc.
is affected by vessel geometry; overall vessel design; 3069 Solomon’s Island Road
closeness to other structures; wind direction; boat speed; Edgewater, MD 21037-1416
and many other variables. In no way can this section www.abyc.com
cover all of the possible variables. Do not rely on this 410-956-1050
section as the exclusive listing of measures to prevent
the accumulation of carbon monoxide.

Consult your boat operators manual for detailed

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

Proper and adequate air circulation, around and

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

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

L510010-09
11
BOATING RESPONSIBILITIES - 2
RULES OF THE ROAD Boat Capacity
Channel Buoy Guide • Load only to manufacturer’s specifications.
• Distribute load evenly; keep it low.
The color of the paint is the only characteristic which • Passengers should only ride on the parts of the
has the same meaning on all buoys. Red buoys always boat that are designed for that purpose.
indicate the starboard side of the channel from seaward. • If water is rough, carry fewer passengers.
(Red Right Returning)
1. Nun Buoy: This buoy indicates the Observe the Rules of the Road
starboard side of the channel when
returning from sea. It is conical shape, PORT (Left) - Leaving the harbor with green buoys to
the color red and indicates even numbers. your right.
A nun buoy with red and green horizontal STARBOARD (Right) - Entering the harbor with red
2 bands (top band red), and not numbered, buoys to your right.
indicates an obstruction. The principal
channel is to the left of the buoy when
returning from sea.

2. Can Buoy: This buoy indicates the port

side of the channel when returning from
sea. It is cylindrical shape, the color green
and indicates odd numbers. A can buoy
with green and red horizontal bands (top
5 band green), and not numbered, indicates Keep to Right
in narrow
Boat being overtaken
has right of way.
Yield to boats
approaching in
an obstruction. The principal channel is to channels. Overtaking boat must this area.
the right of the buoy when returning from stay clear.
sea.
Know Your Horn Signals
3. Lighted Buoy (RED): This buoy has a
flashing red light. It indicates the starboard 1 Short Blast = Passing you on my port side.
side of the channel when returning from 2 Short Blasts = Passing you on my starboard side.
sea. 3 Short Blasts = I am going astern.
5 Short Blasts = Danger.
4. Lighted Buoy (GREEN): This buoy has
Always refer to the latest U.S. Coast Guard Navigation
a quick flashing green light. It indicates
Rules CG-169
the port side of the channel when returning
from sea. The quick flashing light indicates
Keep An Alert Lookout For:
special caution required.
Bad weather, Swimmers, Other boats, Water skiers,
Fisherman, Divers and/or any other obstructions.

Keep Your Wake Under Control, particularly upon

entering or leaving harbor areas. You are responsible
for wake damage to other vessels and/or property.

Small Craft Gale Winds Storm Winds Hurricane Do Not Fool With Fuel
Winds up to 38 - 54 MPH over 55 MPH Winds over 1/2 pint of gasoline = 15 sticks of dynamite
38 MPH 63 MPH
1. During fueling, moor boat properly; remove all
passengers.
2. Keep all doors, hatches and ports closed.
3. Shut down all electronic gear; extinguish galley
fires, pilot lights and smoking materials.
4. Do not overload tanks.
Storm Warning Signals - Pennants (by day)
5. Keep filling nozzles in contact with the fill pipe to
Lights (by night)
prevent sparks.
6. Secure the fill cap tightly; wipe away any spillage.
7. Ventilate all components for a minimum of five
minutes before starting engines.
8. Keep fuel lines and bilges clean.

L510010-09
12
 ENGINE IDENTIFICATION - 3
ENGINE IDENTIFICATION 5.7L 350 c.i.d. Multi-port Fuel Injection
Fuel Recommendations
Unleaded 87 Octane (minimum)
Engine Oil

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

15W-40 above 50 degrees F

When ordering service parts or obtaining information,

5W-30 below 50 degrees F

for your engine have not changed or been omitted.

Marine Gear Oil Recommendation
Dexron III
Electrical Specification

always give the engine model and the serial number.

*Requires Special Diagnostic Tool

12 volts - Negative Ground
Ignition Timing and Engine Idle
Non-Adjustable (See CAM Retard)

This information can be found on the following decal.

Spark Plug P/N and Gap
R030010 - 0.060"
Maximum Engine Speed (WOT)
4800-5200 RPM (5000 RPM Preferred)
Maximum Continuous Cruise
4000 RPM
Firing Order
See Owner's Manual
CAM Retard

0,%!352%#2!&4-!2).%%.').%#/ 0-4 Degrees

Engine Coolant
Dex-CoolTM Long Life

-/$%, 3%2)!, Fuel Pressure - CHECK UNDER LOAD

57-62 psi @ W.O.T. R143170B

HIGHWAY 76 EAST

PCM LITTLE MOUNTAIN

&)2).'/2$%2 1. ENGINE SPECIFICATION DECAL

S.C. 29075

MFR DATE:
MARINE POWER
MODEL SERIAL No

RATIO OIL TYPE:

0,%!352%#2!&4-!2).%%.').%#/
4()3%.').%#/.&/2-34/!,,!00,)#!",%53'/6%2.-%.4
DEXRON III

-/$%, 3%2)!, CHECK OIL LEVEL DAILY

OIL CHANGE AFTER FIRST 25 HOURS OF
&)2).'/2$%2 MFR DATE:
OPERATION AND EVERY 100 HOURS OR 12

34!.$!2$3!.$).4%2.!4)/.!,"/$%.3%%3()00).'
MONTHS, WHICHEVER OCCURS FIRST.
IMPORTANT NOTE: WARRANTY IS VOID IF
4()3%.').%#/.&/2-34/!,,!00,)#!",%53'/6%2.-%.4 MAINTENANCE AND LUBRICATION INSTRUCTIONS
PER PCM MANUAL ARE NOT FOLLOWED.
34!.$!2$3!.$).4%2.!4)/.!,"/$%.3%%3()00).'

#/--)33)/. #/--)33)/.
34!.$!2$#%24)&)#!4)/../- 3. TRANSMISSION
&/2-!2).%%.').%3!44(%$!4%/&-!.5&!#452%
34!.$!2$#%24)&)#!4)/../- ,)44,%-/5.4)!.3# IDENTIFICATION PLATE
2. ENGINE IDENTIFICATION DECAL
&/2-!2).%%.').%3!44(%$!4%/&-!.5&!#452%
,)44,%-/5.4)!.3#

Figure 3-1 Engine Identification Decal 1

2

OWNER IDENTIFICATION AND REGISTRATION

INFORMATION
3
We suggest that you record the following information 2

for quick reference when ordering parts or requesting

service or warranty.

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

PORT STARBOARD

Engine Model Number:

Serial Number(s):

Gear Model Number:

Serial Number(s):

Boat Make:

Boat Model:

Hull Serial Number:

Propeller Size:

Ignition Key Number:

L510010-09
13
ENGINE IDENTIFICATION - 3
PCM
ENGINE MODEL IDENTIFICATION / ADVISORY

MODEL 0 2 - 6 0 1 V - 0 1 SERIAL 490000

1st - 2nd Space: MANUFACTURING CODE

*SERIAL NUMBER I.D.*
3rd - 5th Space: ENGINE CODE 1st DIGIT INDICATES DECADE ENGINE WAS
601 = 6.0L (364 CID MPI) (LY6 Base) (GM) MANUFACTURED ( 3 = 1990, 4 = 2000, 5 = 2010 )
570 = 5.7L (350 CID LH MPI) (GM) 2nd DIGIT INDICATES CALENDAR YEAR ENGINE WAS
500 = 5.0L (305 CID LH MPI) (GM) MANUFACTURED.
6th - 7th Space: DRIVE CONFIGURATION
blank - Direct Drive
V - V-Drive
C - Clean Emissions System (CES)

8th - 9th Space: SPECIFICATION CODE

L510010-09
14
 ELECTRONIC FUEL INJECTION INFORMATION - 4
ELECTRONIC FUEL INJECTION SYSTEM
The PCM Engines covered in this manual are equipped
with an Electronic Fuel Injection (EFI) system, which
allows precise control of fuel and spark delivery. The
fuel system components of the EFI system are:
• The electric fuel pumps
• The throttle body assembly
• The fuel injectors
The fuel injection system is controlled by an Electronic
Control Module (ECM). The ECM is the decision center
of the system. The ECM constantly monitors information
from various sensors on the engine, and electronically
processes the information, in order to control ignition
timing and fuel delivery for optimum performance
and fuel economy. The ECM incorporates an engine
overspeed protection, calibrated to a specific RPM, to
prevent engine damage from over-revving.
The sensors that the ECM monitors are:
• Engine Coolant Temperature (ECT) Sensor
• Throttle Position (TP) Sensor
• Manifold Absolute Pressure (MAP) Sensor
• Knock Sensor (KS) System
• Crankshaft Positioning (CKP) Sensor
• Camshaft Positioning (CMP) Sensor
• Intake Air Temperature (IAT) Sensor
• Throttle Control Position (TCP) Sensor
Additional Sensors for CES ENGINES
• Pre-Catalyst Oxygen (O2) Sensors
• Post-Catalyst Oxygen (O2) Sensors
• Exhaust Manifold Water Temp (EMWT) Sensors
If, for any reason, one or more of these sensors or
associated wiring malfunctions, the ECM’s built-in self-
diagnostic system sets a trouble code and turns on the
“MIL” Malfunction Indicator Lamp to alert the operator of
a malfunction.
In most cases, when the “MIL” is on, the engine(s) may
lose some performance and/or efficiency, but remain
running adequately. Also, the light may go out or
become intermittent, but a trouble code will be logged for
future diagnosis. (See Engine Alarm System - page 16)
In any case, the operator must obtain service by an
authorized PCM Premier dealer to determine the exact
cause of the malfunction.

L510010-09
15
OPERATING INSTRUCTIONS - 5
ENGINE ALARM SYSTEM The alarm circuit has a “self” checking feature
programmed into the system. This feature will light the
The PCM engine electronic system is programmed to “MIL” and “CGL” lamps, and also sound the buzzer for
control the engine alarm system. This system utilizes two short pulses upon initial start-up of the engine.
an indicator lamp (“MIL” or “Check Engine”) and/or an
NOTE: If, during Key ON, engine OFF, either the MIL
optional audible alarm to warn the operator of possible
or CGL lamps are flashing, this indicates that a stored
engine problems.
trouble code or engine fault is recorded in the ECM.
The alarm circuit has a “self” checking feature Refer to your dealer for proper diagnosis.
programmed into the system. This feature will
If the “MIL” or “CGL” lights and the alarm sounds during
momentarily light the “MIL”, and if equipped, sound the
operation, observe the instrument panel readings for
alarm for two short pulses upon initial start-up of the
the possible source of the malfunction, such as low oil
engine.
pressure or excessive engine temperature readings.
If the “MIL” lights and/or the alarm sounds during
Other conditions that may sound the warning buzzer are
operation, observe the instrument panel readings for
a transmission over-temperature warning (if equipped),
the possible source of the malfunction, such as low oil
exhaust manifold water over-temperature warning , and
pressure or excessive engine temperature readings.
for an electronic throttle malfunction.
Other conditions that may sound the warning buzzer are
IMPORTANT: A failure involving the Electronic Throttle
a transmission over-temperature warning (if equipped),
may result in Idle only operation of the engine. The
exhaust gas over-temperature warning (if equipped), and
operator must obtain service by an authorized PCM
for an electronic throttle malfunction.
Premier dealer to determine the exact cause of this
ENGINE ALARM SYSTEM (CES ENGINES) malfunction as soon as possible.
In most cases, when the “MIL” or “CGL” lights are on, the
The PCM engine electronic system is programmed to engine may lose some performance and/or efficiency,
control the engine alarm system. Your CES Engine but remain running adequately. Also, the lights may go
Alarm System may utilize up to three (3) alarm circuits to out or become intermittent, but a trouble code will be
warn you of a potential problem with your engine. logged for future diagnosis.
The Malfunction Indicator Lamp (MIL) is used for In any case, the operator must obtain service by an
notification of any emissions-related fault. This is an authorized PCM Premier dealer to determine the exact
amber indicator lamp, that may be labeled ‘Service cause of the malfunction.
Soon’ or with the ISO icon, to warn the operator of
possible engine problems. NOTICE: Some boat builders may install their own

ISO Icon
The Check Gauges Lamp (CGL) is used for notification
of any non-emissions-related fault. This is a red
indicator lamp to warn the operator of possible
engine problems such as low oil pressure or an over
temperature condition.
The Buzzer is an audible notification to the operator, that
may be used in conjuction with the MIL and/or CGL.
For events such as an engine over-temperature
condition, low oil pressure, etc., the Buzzer will sound
for 1/2 second ON, 1/4 second OFF, continuously as an
audible warning. For emissions related faults (MIL), the
buzzer will initially sound for 5 seconds, then will sound
for 1/2 second ON once per minute thereafter. In the
event of a MIL circuit failure, MIL circuit functions will be
transferred to the Buzzer circuit.

L510010-09
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 OPERATING INSTRUCTIONS - 5
INSTRUMENTATION
CHECK
40 13
Boat manufacturers install many different types of 0
80
ENGINE
10 16

instrumentation on boats. Become familiar with the OIL VOLT

instrumentation on your boat and be aware of abnormal

operating conditions. The following is a brief explanation 20 30
10 40
of typical instrumentation found on most boats:
0 50
170 1/2
1. Tachometer - indicates the engine RPM 100 200 E F

(revolutions per minute) TEMP 60 FUEL

TACH
2. Water Temperature Gauge - indicates the engine
coolant temperature
3. Oil Pressure Gauge - indicates the engine oil Figure 5-1 Typical Instrument Panel
pressure
MALFUNCTION INDICATOR LAMP CHECK GAUGES LAMP
4. Voltmeter - indicates the battery voltage and MIL CGL
charging system voltage
5. Hour Meter - indicates the engine operating time
6. Fuel Level Gauge - indicates the fuel tank level
7. Malfunction Indicator Lamp (MIL) or Check
Gauges Lamp - indicates a problem with the
engine control system
Notice: Many boat manufacturers are using Controller
Area Network (CAN) based instrumentation. This
instrumentation is driven by a two-wire network from Figure 5-1A Typical Warning Lamp Cluster -
the engine. Refer to your boat manufacturers Owners CES Engines
manual for the type of instrumentation being used with
your application. STARTING ENGINE (FUEL INJECTED ENGINES)

ELECTRONIC SPEED CONTROL (IF EQUIPPED) WARNING

This engine is equipped with a Digital Throttle Control Before starting engine, ventilate the engine
(DTC) system. The system uses a throttle cable compartment by operating the bilge blower for
connected between the throttle handle and a Throttle a minimum of five minutes to remove any gas
Control Positioning (TCP) sensor located on the engine. fumes from the engine compartment. If the boat
The Throttle Control Positioning sensor provides throttle is not equipped with a blower, open the engine
position information to the engine management system compartment hatches to ventilate and leave open
which, in turn, electronically controls engine throttle while starting engine.
movement.
IMPORTANT: Do not start the engine without water
This boat may also be equipped with an electronic
being supplied to the sea water pick-up pump or
speed control system for skiing, wake boarding, or cruise
sea-water pump impeller will be damaged, and
control. When the boat is operated in a speed control
subsequent overheating damage to the engine may
mode, the operator may not have full control of the
result.
throttle until the speed control system is deactivated.
IMPORTANT: The following items should be
Example: If the speed control system is engaged at 32
checked before starting the engine, and each time
mph, the throttle handle may be “dead” when trying to
the boat is operated:
accelerate above 32 mph. The speed control system
would need to be disengaged, then the operator will gain • Fuel system for any signs of leakage
full control of the boat speed. • Operation of remote controls and steering
Refer to your Boat Manufacturers Owners/Operation • Engine and transmission oil levels
manual for specific operation and troubleshooting
information for your speed control system. • Fuel tank levels
• Exhaust system for leaks and tightness of the
clamps

L510010-09
17
OPERATING INSTRUCTIONS - 5
• Battery connections and water level in battery
cells
• Accessory drive belt(s)
• Cooling system for leaks. If equipped with fresh-
water cooling, check coolant level in recovery Check for
bottle. Check for signs of water leaks at the signs of
external leaks Check for
exhaust manifolds, risers and elbows (Figure 5- signs of
2). If the water is leaking externally, it is possible external leaks
that the water is also leaking internally. This
could result in internal engine damage. It is very
important to service these maintenance items as
soon as a problem is indicated. After performing
the initial safety checks, proceed as follows to
start the engine: Figure 5-2 Water Leaks
1. Turn the battery switch ON (if equipped).
2. Open the fuel valve. WARNING
3. Open the seacock. The machinery space must be closed anytime the
4. Place the remote control in Neutral position. The engine is running to prevent injury to you or others
transmission is equipped with a neutral safety on board. Never operate the engine with the engine
switch, which will not allow the starter motor to machinery space open while someone is in the
operate unless the transmission is in neutral. machinery space, either closed or open. Never
open the machinery space unless the engine is shut
5. Do not pump or open the throttle when off and the engines rotating parts are stationary.
starting the engine (Figure 5-3). The ECM Rotating machinery can cause injury and even death
will automatically regulate the fuel and control if an accident should occur. Extreme care must be
desired idle speed. exercised if a problem exists that requires operation
PCM has introduced a product enhancement feature on of the engine with the machinery space open. IT IS
all PCM Mulitport Fuel Injection Products. Your engine RECOMMENDED THAT UNCOVERED ENGINE
may be equipped with the engine auto-crank feature. OPERATION BE ATTEMPTED BY TRAINED AND
This feature allows the engine to automatically crank, QUALIFIED SERVICE PERSONNEL ONLY.
or turn over, when commanded. Once the operator has
turned the key to the START position on a key switch, or 6. Turn the ignition key to the start position. When
depressed the START button on a touchpad, the engine the engine starts, release the key.
will automatically turn over and start. The engine will turn NOTICE: Engine idle speed is controlled by the ECM
over until the engine starts, or a maximum of 5 seconds. and is based on the operating temperature of the engine.
The key switch or stop button can always be utilized in Upon initial start-up, engine RPM will be slightly higher
order to cease the engine from cranking and/or starting. and will automatically decrease as the engine operating
Important: In the event that the engine must be turned temperature increases.
over WITHOUT automatically cranking or starting (i.e. 7. In the event the engine becomes flooded,
bumping the engine to #1 position or performing a ensure the Neutral Lockout is engaged and move
compression check) a remote starter button MUST be the throttle lever to a 100% open position (Figure
used, connected directly to the starter solenoid and the 5-3). At this throttle position, the ECM will
ignition system disabled. command the injectors to deliver no fuel during
engine cranking. When the engine starts, return
the throttle lever back to the idle position.
NOTICE: Single lever throttle/shift handles use different
mechanisms to achieve Neutral Lockout or throttle only
operation. Some require you to push in on a button
while moving the handle forward, others require the
button to be pulled out. Refer to your boat owners
manual for complete instructions on throttle/shift lever
operation.

L510010-09
18
 OPERATING INSTRUCTIONS - 5
FORWARD SHIFT NEUTRAL REVERSE SHIFT RANGE
RANGE

IDLE IDLE

FORWARD REVERSE
THROTTLE THROTTLE
RANGE RANGE

NEUTRAL
LOCKOUT

SAFETY
COLLAR

FULL FULL
THROTTLE THROTTLE
Figure 5-3 Typical Throttle / Shift Position Settings
IMPORTANT: If the engine fails to start within 20-30 SHIFTING TRANSMISSION
seconds, turn the ignition key to the OFF position
and allow 2 minutes for the starter motor to cool off CAUTION
before attempting to restart the engine.
NOTICE: If engine still fails to start, contact your PCM Never shift the transmission into or out of gear
Engines Dealer for service. unless the throttle is at the idle position. Shifting the
transmission above 1000 RPM can severely damage
8. Check engine oil pressure immediately after
the boat, transmission and engine.
the engine starts. If oil pressure is not within
specifications (see Engine Specifications), 1. Set the throttle lever at the idle position.
immediately stop the engine and determine the
cause. 2. Pull up on the Safety Collar and slowly push the
throttle/shift handle into the Forward gear Idle
9. Check voltmeter for proper charging system position.
operation.
Throttle may be increased/decreased as required in the
10. Check the engine and transmission for fuel, oil, Forward Throttle Range.
water and exhaust leaks.
3. Pull up on the Safety Collar and slowly pull the
11. Allow the engine to reach normal operating throttle/shift handle back into the Reverse gear
temperature. Check the temperature gauge Idle position.
to ensure the engine is operating within the
normal temperature range. If the temperature Throttle may be increased/decreased as required in the
is abnormally high, stop the engine immediately Reverse Throttle Range.
and determine the cause. 4. Move the transmission lever to the center detent
position to shift into Neutral.

L510010-09
19
OPERATING INSTRUCTIONS - 5
SHIFTING 2-SPEED TRANSMISSION STOPPING ENGINE

Your application may consist of a 2-speed transmission. When returning to the dock, or whenever stopping the
engine, bring the throttle back to the idle position and the
Philosophy of two speed gearbox usage: transmission to Neutral. After the engine reaches idle
• 1st gear is used for accelerating the boat and for speed, turn the ignition key to the OFF position.
cruising at medium - low speed
Before stopping the engine after extended high speed
• 2nd gear is used for cruising at medium - high operation, allow the engine to idle at 1200 RPM for 3 to 5
speed minutes to allow the engine to cool down before shutting
off the ignition.
Important operating notes:
• acceleration of engine rpm in 1st gear is allowed After stopping the engine, complete the following:
up to 100% engine rpm
1. Turn the battery switch OFF, if equipped.
• shifting from 1st gear to 2nd gear (up-shifting) has
to be done making a light deceleration of engine
2. Close the fuel valve.
rpm
• shifting from 2nd gear to 1st gear (down-shifting) 3. Close the seacock.
has to be done decelerating engine rpm, under
1600 rpm and with a considerable reduction of boat 4. Flush the cooling system if in a salt water area.
speed. Further re-acceleration has to be gradual.

FREEZING TEMPERATURE OPERATION

If the possibility of freezing exists, the cooling system

must be protected after the engine is shut off to prevent
freeze damage to the engine. Refer to OUT-OF-
SEASON STORAGE for draining instructions.

OPERATION IN HIGH DEBRIS AREAS

If the boat is to be operated in high debris areas, a sea

strainer should be installed in the water inlet hose to
prevent debris from entering the cooling system. The
strainer used must be of sufficient size to allow an
adequate supply of water for cooling the engine. A
minimum of 30 gallons per minute (114 liters per minute)
flow rate is required.

L510010-09
20
 OPERATING INSTRUCTIONS - 5
PCM BASIC CRUISE SPEED CONTROL SYSTEM
(OPTIONAL) Cruise
Cruise Mode allows electronic control of the engine at an
operator selected boat or engine speed. The operator
has the option of entering Cruise Mode one of two ways. MPH Set (+)/Res
MPH Mode allows the operator to set a cruise speed
based on boat speed. RPM Mode allows the operator
to set a cruise speed based on engine RPM. When
you are in Cruise Mode, the engine is electronically
controlled to maintain the desired MPH selected, or Cruise Speed Speed
engine RPM, regardless of sea conditions or maneuvers.
MPH CRUISE MODE
When the Basic Cruise System is operated in the MPH
Mode, the operator will select the desired boat speed he
wishes to maintain. Boat speed information is provided RPM Cancel (-)
to the ECM via the paddle wheel. The paddle wheel is
the same device that provides speed information to the
boat’s speedometer. As load conditions change on the
Figure 5-4 PCM Basic Cruise Control Panel (Typical)
boat, such as a skier or wake boarder pulling against the
boat or the boat entering / exiting a turn, the speed of operator selected point. As load conditions change on
the boat typically will vary; however, the ECM monitors the boat, such as a skier or wake boarder pulling against
these variations based on the paddle wheel input and the boat or the boat entering / exiting a turn, the speed of
responds by increasing or decreasing engine RPM to the boat typically will vary; however, engine RPM should
maintain the operator selected boat speed. remain at the operator selected point.
IMPORTANT: If the paddle wheel input is lost, while ENTERING CRUISE MODE
operating in the MPH Cruise Mode, engine RPM will 1. Select the desired cruise mode by pressing the
increase by approximately 60 rpm. The operator will MPH/RPM Cruise switch to the MPH or RPM
feel this as a ‘bump’ as boat speed increases and position.
the MIL or Check Engine Lamp will be lit. Speed
will remain constant at this new point. If the paddle NOTE: The Cruise Lamp should be OFF. If the Cruise
wheel input is re-established, boat speed will drop to lamp is blinking, the system has “remembered” a set
the operator set point and the MIL will turn OFF. speed from a previous Cruise Mode operation. If this
speed is unknown, or is not the desired set speed,
If you enter MPH Cruise Mode and there is no input simply press the Speed Cancel switch and the lamp will
from the paddle wheel, when you set a new speed turn OFF.
or resume the previous set speed, the system will
initially hold the set speed then slowly begin to ramp 2. Move the throttle to the desired speed.
the speed up to throttle handle position and turn on 3. Press the Speed Set switch. The Cruise Lamp
the MIL. Pull the throttle handle back and exit MPH will blink until the throttle handle is moved above
Cruise Mode. RPM Cruise Mode is not affected by the set point. Push the throttle handle to the full
the loss of the paddle wheel input. forward position.
With the engine off and the boat on a lift or the NOTE: The throttle handle should be in the full forward
trailer, inspect the paddle wheel for damage or position at this time. This allows the electronic control
blockage. If you are unable to correct the problem sufficient range to adjust and maintain the engine at the
at the paddle wheel, contact your authorized PCM desired set speed.
Premier Dealer for service.
4. The Cruise Lamp should be steady ON indicating
RPM CRUISE MODE that Cruise Mode is engaged.
When the Basic Cruise System is operated in the 5. Pressing the Speed (+)/Res (Increase/Resume)
RPM Mode, the operator will select the desired engine or (-) (decrease) switch allows the operator to
RPM he wishes to maintain. Engine speed or RPM adjust the set speed up or down 20 RPM, or.25
information is monitored by the ECM, and is the same MPH, each time the switch is engaged.
signal information the ECM provides to drive the NOTE: Depressing and holding the Speed (+)/(-) switch
Tachometer on the instrument panel. The ECM monitors for 3 seconds or longer will cause the speed to slowly
the tach signal and maintains engine RPM at the ramp up ((+)/Res) or down (-). Release the switch when

L510010-09
21
OPERATING INSTRUCTIONS - 5
the desired speed is achieved, this will be the new set
speed. Cruise

CANCELLING THE CRUISE SET-POINT

MPH Set (+)/Res
1. Press the Speed Cancel switch.
2. Pull the throttle handle back below the set point.
3. The Cruise Lamp will go OFF indicating that the
operator has full throttle control over the engine.
IMPORTANT: The ECM ‘remembers’ the previous Cruise Speed Speed
set point of a Cruise Mode operation. This means that
you may have two set points in memory, one for MPH
Mode and one for RPM Mode. ONLY the Cruise speed
set-point for the current cruise mode (MPH or RPM)
has been cancelled. At this point, a new set speed
RPM Cancel (-)
could be selected, you may use the Resume Mode to
go back to the previous set speed, or you could change
cruise mode and use Resume or Set Speed in the newly
selected cruise mode. Figure 5-4 PCM Basic Cruise Control Panel (Typical)
RESUME MODE blinking and as the throttle handle is pushed forward
1. After cancelling a Cruise Mode set speed, the past the previous set point, cruise would resume.
previous set speed can be resumed by pressing If the Cruise lamp is flashing when you re-start
the Speed (+)/Res switch, then pushing the the engine, simply press the Speed Cancel switch,
throttle handle forward above the previous Cruise or turn the Cruise Mode switch OFF, to regain full
set-point. throttle control .
NOTE: The operator may disengage Cruise Mode at The ECM remembers the last programmed Cruise
any time by pulling the throttle handle back below the set speed, even if the Speed Cancel switch has been
point. The Cruise lamp will flash indicating that Cruise pressed. If you wish to resume Cruise Mode at
Mode is still requested, but not engaged. If the throttle the previously selected speed, select the desired
handle is pushed forward past the previous set-point, cruise mode (MPH or RPM, if the switch is in the
while the Cruise lamp is blinking, Cruise will Resume OFF position), then press the Speed (+)/Res switch,
at the previous set-point, and the Cruise lamp will be the Cruise Lamp will begin flashing and Cruise will
steady ON. be engaged when the throttle handle passes the
previous set-point. Or, you may set a new Cruise
EXITING CRUISE MODE
speed by pressing the Speed Set switch at the new
1. Press the MPH/RPM switch to OFF. desired engine speed.
2. The Cruise Lamp will go OFF. Cruise mode
will remain engaged until the operator pulls the
throttle handle back below the set point.
IMPORTANT: It is good practice to always exit
Cruise Mode properly, prior to shutting off the
engine. If the engine is turned off while the Cruise
Mode switch is in MPH or RPM Mode, the ECM is
still being commanded to be in the Cruise mode.
The ECM remembers the last set speed for each
cruise mode and the last switch command prior to
being shut off. When the engine is re-started, Cruise
Mode will be resumed. If Speed Cancel was the last
operation prior to turning the engine off, the Cruise
Lamp will be off. If the operator simply pulled the
throttle back to neutral and shut off the engine while
cruise mode was engaged, the Cruise Lamp will be

L510010-09
22
 CONDITIONS AFFECTING OPERATION - 6
TRIM AND WEIGHT DISTRIBUTION BOAT BOTTOM

Trimming of the boat and positioning of the weight (gear To ensure maximum engine performance, fuel economy
and passengers) inside the boat has the following effects and boat speed, the bottom of your boat must be kept
on handling: clean and free of marine growth and barnacles. Marine
vegetation may accumulate when the boat is docked
• Trimming the bow up or shifting weight to the and should be removed before operation. If the boat
stern (rear). is docked for long periods of time, the water inlets may
become clogged with growth and will cause the engine
− Normally used for cruising (running) with a to overheat.
choppy wave condition (following sea) for
running at full speed. In most areas, it is advisable to coat the boat bottom with
antifouling paint to prevent the build-up of marine growth.
− Will generally increase speed and engine Contact your dealer for advice on these requirements in
RPM. your area.

− Will cause the bow to bounce in rough water.

− In extreme, may cause the boat to porpoise.

− When coming off plane, it increases the

chances of following wave splashing into the
stern of the boat.

• Trimming the bow down or shifting the weight to

the bow (front).

− Normally used for cruising (running) against

a choppy wave condition, acceleration onto
plane and operating at slow planing speeds.

− Will improve rough water ride and handling.

− In extreme, may cause the boat to bow steer

(veer back and forth with little control).

L510010-09
23
CONDITIONS AFFECTING OPERATION - 6
PROPELLER SELECTION If full throttle RPM is above or below the recommended
range as stated in ENGINE SPECIFICATIONS,
Best all-around performance and maximum engine life is the propeller must be changed to prevent loss of
achieved when the engine is propped to run near the top performance. A one-inch change in the pitch of a given
of (but within) the recommended full throttle RPM range propeller will generally change engine RPM by 150 to
with a normal load. See ENGINE SPECIFICATIONS for 250 RPM.
rated full throttle RPM for your model engine.
ENGINE RPM CHART
Generally, gross weight (total weight of the entire Minimum
boat, including full fuel and water, optional equipment, Model Full Load Preferred Maximum
passengers and other miscellaneous gear) is one of
the major factors and should be one of the primary CES 5.0L
considerations when selecting a propeller. Other factors and 4600 4800 5000
to take into consideration are as follows: MP 5.0L

• Warmer weather and higher humidity will cause CES 5.7L

an RPM loss. and 4800 5000 5200
MP 5.7L
• Operating the boat in a higher elevation will
cause an RPM loss. CES 6.0L
and 5200 5500 5600
• Operating the boat with an increased load MP 6.0L
will cause an RPM loss (additional equipment, (ZR409)
passengers, etc.).

CAUTION

Prolonged WOT operation will shorten the life of

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

IMPORTANT NOTICE: Your new PCM engine

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

L510010-09
24
 ENGINE BREAK-IN PERIOD - 7
WARNING CAUTION

Use this procedure ONLY when conditions are such DO NOT attempt to break in any engine by prolong
that it can be done in complete safety. idling, or running at the dock.

The break-in period of your engine is the first 25 hours The engine oil level should be checked often and oil
of operation. Proper engine break-in is essential to added when necessary. It must be understood that
achieve maximum performance, longevity and minimum every internal combustion engine will use a certain
oil consumption. During the break-in period, the amount of oil during operation to act as a lubricating
following operation guidelines must be adhered to: and cooling agent, especially during the break-in period.
Oil consumption should decrease and become stabilized
• After the engine is thoroughly warmed up, and after approximately 100 hours of operation.
the boat is underway, open the throttle to wide
open throttle until maximum RPM is reached. DO At the end of your 25-hour break-in period, contact your
NOT EXCEED MAXIMUM RPM. (RPM should dealer and have the recommended 25-hour inspection
cease climbing after 10 to 20 seconds). done.

CAUTION NOTICE: PCM Engines assumes no responsibility for

the costs related to the 25-hour inspection. This is the
DO NOT operate at full throttle in neutral at any time, owner’s responsibility.
or at sustained full throttle during the first 5 hours
of operation. Thereafter, use sustained wide open
throttle in the event of an emergency.

• Reduce the throttle to 2800 - 3000 RPM, and

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

• During the remaining 20 hours of break in period,

the engines can be run at cruise speeds that are
approximately 75-80% of the wide open throttle
RPM, occasionally varying the cruise speed by
100 RPM.

• During the early part of the break in period, the

correct propeller selection can be confirmed.
(With a normal load aboard, the engine’s RPM
should reach, but not exceed, the maximum RPM
as listed in the specifications section).

• During the break in, all gauges should be

watched carefully, and the speed should be
reduced if abnormal readings become evident.

L510010-09
25
25-HOUR ENGINE INSPECTION - 8
After the first 25 hours of operation, it is recommended • Cooling System - Inspect all the hoses for leaks,
that the engine be given an inspection. Your boat dealer damage and deterioration. Check all the hose
or a PCM Premier servicing dealer should be contacted clamps for adequate tightness.
to perform the necessary checks and adjustments to
ensure the proper engine performance. The following • Exhaust System - Inspect the entire exhaust
maintenance should be performed: system for leaks, damage and deterioration.
Check all the hose clamps for adequate
• Change the engine oil and filter. tightness.

• Replace the primary fuel filter • Battery - Check the electrolyte level and specific
gravity. Inspect the case for damage. Check the
• Check the engine alignment. battery cables and connections.

• Inspect the accessory drive belt(s) and check the • Engine Assembly - Check for loose, missing
tension. or damaged parts. Pay close attention to
engine mounts, starter and alternator mounting
• Check all the fluid levels. fasteners.

• Check the throttle and the shift cable adjustments NOTICE: PCM Engines assumes no responsibility for
and check for freedom of movement. the costs related to the 25-hour inspection. This is the
owner’s responsibility.

L510010-09
26
 FUEL REQUIREMENTS - 9
GASOLINE REQUIREMENTS GASOLINE CONTAINING ALCOHOL
The implementation of ethanol-based fuel is spreading
CAUTION
rapidly throughout the United States. As such, PCM
Fire and Explosion Hazard - Gasoline is extremely Engines provides the following information regarding the
flammable and highly explosive, and , if ignited, use of this fuel.
can cause serious bodily injury or death. Careful This information addresses the use of ethanol fuels in
inspection of the entire fuel system including, but PCM ENGINES ONLY. It does not address the use of
not limited to, fuel tanks, fuel lines, fuel filters and ethanol fuels in vessel related components such as boat
all fittings is mandatory, especially after periods gas tanks, boat fuel lines, etc.
of storage. Replace any component that shows
Ethanol blended fuel rated E10 or less is acceptable
signs of leakage, corrosion, deterioration, swelling,
to use. Fuels rated higher than E10 SHOULD NOT
hardening or softening.
BE USED. Ethanol fuels rated higher than E10 could
WARRANTY NOTICE: Damage caused to the engine potentially damage the engine and/or present an
through the use of improper gasoline, low-quality or unsafe boating condition. Damage to the engine
gasoline with an octane rating below the minimum resulting from the use of ethanol fuel rated higher
requirements listed below, is considered misuse of than E10 IS NOT covered by the warranty.
the engine. Such damage is not covered by the PCM
Marine Engines warranty. CAUTION
The ignition timing set by the factory requires the use
Do Not use any gasoline that contains
of a high-quality lead-free regular gasoline with the
METHANOL. This fuel is very corrosive and will
following minimum octane specification.
create unsafe operating conditions. Serious
Pump Octane Number (R+M/2) (PUMP) - 87 damage will result from the continued use of fuel
containing METHANOL. Any resulting engine
damage will not be covered by the warranty.
E D
L E AD
U N $ If ethanol blended fuel rated E10 or less is used, or
if the presence of alcohol is uncertain, more frequent
D
DE
LEA R
UN GULA
RE
inspections and service of the complete fuel system are
87 MINIMUM OCTANE RATING required. Any sign of fuel leakage or deterioration must
R + M/2 METHOD
be repaired immediately before further engine operation.

E10 87 It is important to note that ethanol blended fuel will act

as a solvent and will attract and hold moisture. Without
proper fuel stabilization and fuel filtration, ethanol
blended fuel may cause the following:
• Excessive moisture (water) may cause lean
operation to include hard starting and operating

E10 •
difficulties such as, vapor lock, low speed
stalling, and shortened fuel shelf life.
Acting as a solvent, ethanol blended fuel may
cause gum, sediment, sludge, and other particles
Figure 9-1 Fuel Requirements to be loosened and carried through the fuel
NOTICE: PCM Fuel Injected engines are calibrated system to the engine.
to operate on and provide optimum performance when Fuel system or engine damage caused by
using fuel with at least an 87 octane fuel rating. PCM’s contamination from water, foreign particles, sludge,
engine contorl module incorporates Adaptive Learn or gums entering or forming in the fuel system is not
Technology to ensure optimum engine performance is covered by the PCM Limited Warranty.
obtained when using fuel rated higer than 87 octane.
Fuel Stabilizer Recommendations for Ethanol
If a slight pinging is heard during acceleration and the
proper octane fuel is being used, it is considered normal. Blend Fuel
If a constant, heavy knock occurs, the engine should be The use of a commercially available fuel stabilizer, such
evaluated by a PCM Marine Engines Premier service as STA-BIL®, is recommended at each fill-up or when
technician. storing ethanol-blended fuel for more than 2 weeks.

L510010-09
27
OIL REQUIREMENTS - 10
ENGINE OIL RECOMMENDATIONS WARRANTY NOTICE: PCM Engines reserves the right
to refuse warranty on part(s) and/or engine(s) damaged
Use of Supplemental Additives by using improper fuels and engine oils.

Engine oils meeting PCM Engines’ recommendations Oil Change Intervals (Common)
already contain a balanced additive treatment. The
use of supplemental additives which are added to the Crankcase oil and oil filter change - Recommended
engine oil by the customer are unnecessary and may intervals:
be harmful. PCM Engines does not review, approve or
recommend such products. • Initial oil change - 1st 60 days or 25 hours of
operation, whichever occurs first
Synthetic Oils
• Regular oil changes - Every 50 hours of
Synthetic engine oils may be used in PCM Marine operation or 120 days, whichever occurs first
Engines. Synthetic oils must meet the Engine Oil
Requirements for Classification and Viscosity listed TRANSMISSION AND “V”-DRIVE OIL
below. The use of synthetic oil does not permit the REQUIREMENTS
extension of oil change intervals.
Recommended A.P.I.
Engine Oil Requirements Transmission Classification and
and “V” Drive Viscosity
The following chart shows the recommended oil viscosity
for various ambient temperature ranges: PCM Dexron III Automatic
Transmissions Transmission Fluid (ATF)
Prevailing Ambient Recommended A.P.I. or equivalent
Temperature Classification & Viscosity
PCM V-Drive Mobiltrans SHC 50
Above 50˚F SAE 15W-40 “GF-4/SM” Transmissions Synthetic Transmission
Lubricant (R190250)
Below 50˚F SAE 5W-30 “GF-4/SM”

IMPORTANT: The use of oils which contain “solid” Walters “V”-Drive SAE 30
additives, non-detergent oils or low quality oils
specifically are not recommended.
Dexron III Automatic
All Hurth Gear Transmission Fluid (ATF)
Transmissions or equivalent

L510010-09
28
 ENGINE MAINTENANCE - 11
ENGINE MAINTENANCE
Refer to the MAINTENANCE SCHEDULE for a complete
listing of required maintenance and the frequency at
which it should be performed. While some procedures
may be performed by the owner/operator, PCM
Engines strongly recommends that all engine service
and maintenance be performed by an authorized
PCM Engines Premier Dealer. Before performing any
maintenance or repair procedure not covered in this
manual, it is strongly recommended that a PCM Engines
repair manual be purchased and read thoroughly.
CHECKING FLUID LEVELS
Engine Crankcase Oil

CAUTION
ENGINE OIL
Do Not overfill engine crankcase with oil. DIPSTICK
Excessive oil can lead to premature engine
component failure and/or loss of performance. DIPSTICK
OPERATING
IMPORTANT: The engine oil level must be checked RANGE
while the boat is in its normal, level, at rest position
on the water. Excessive wave action side to side
or fore and aft may cause you to obtain erroneous
readings. If the oil level is being checked while
the boat is on a trailer, ensure the trailer is on level FULL MARK
ground, then adjust the trailer so the boat is at its ADD MARK
normal, at rest position. Excess water in the bilge Figure 11-1 Engine Oil Dipstick (Typical)
and, if equipped, ballast systems must be purged
when checking the engine oil level, otherwise
erroneous readings may be obtained. WARNING
1. Stop the engine, if running. Allow approximately
The machinery space must be closed anytime the
5 minutes for the oil to drain back into the oil pan.
engine is running to prevent injury to you or others
2. Remove the dipstick, wipe it clean, and reinstall on board. Never operate the engine with the engine
it until it is within two (2”) inches of being fully machinery space open while someone is in the
seated. Slowly move the dipstick up and down machinery space, either closed or open. Never
approximately one-half (1/2”) several times; then open the machinery space unless the engine is shut
fully seat the dipstick into the dipstick tube. off and the engines rotating parts are stationary.
3. In order to obtain an accurate reading, wait two Rotating machinery can cause injury and even death
minutes for the oil to stabilize on the dipstick. if an accident should occur. Extreme care must be
Remove the dipstick and observe the oil level. exercised if a problem exists that requires operation
The oil level must be between the “FULL” and of the engine with the machinery space open. IT
“ADD” marks. If the oil level is below the “ADD” IS RECOMMENDED THAT UNCOVERED ENGINE
mark, add specified oil to bring the level up to, OPERATION BE ATTEMPTED BY TRAINED AND
but not over, the “FULL” mark on the dipstick. QUALIFIED SERVICE PERSONNEL ONLY.
If the oil level is above the “FULL” mark on the
dipstick, remove the excess oil. (Figure 11-1)

L510010-09
29
ENGINE MAINTENANCE - 11
Transmission Fluid Hurth Transmission

CAUTION WARNING
PCM Engines uses marine transmissions supplied Do not attempt to remove the transmission dipstick
by several manufacturers. The maintenance while the engine is running. Hot transmission fluid
requirements can be different between these could be sprayed from the dipstick hole.
manufacturers. It is important that you refer to
the operation and maintenance manual supplied by 1. Remove the dipstick by turning the T-handle
the transmission manufacturer before you attempt counterclockwise. Observe the fluid level.
to perform maintenance on your own. If no Replace the dipstick and tighten securely.
maintenance manual is available, PCM Engines
recommends that you contact your dealer service 2. Operate the engine until the engine and the
department for any required maintenance or service transmission reach operating temperature.
instructions.
3. Stop the engine and quickly check the fluid level
PCM Transmissions
to minimize the drain-back from the oil cooler.
1. Engine must be running at operating Remove the dipstick by turning the T-handle
temperature. counterclockwise. Wipe the dipstick off with a
clean cloth. Re-insert the dipstick to the threads
2. Shift at least once into forward, once in reverse, (do not screw the dipstick in) and remove the
then back to neutral. dipstick. Observe the fluid level.

3. With the engine running, and the prop shaft not 4. The fluid level should be at the “FULL” or “MAX”
turning, install the dipstick in all the way. mark. If low, add the specified fluid through the
dipstick tube. Repeat checking procedures as
4. Remove the dipstick and check the fluid level. required until the fluid level is at the “FULL” or
The dipstick should read FULL. “MAX” mark.

5. If the fluid level is low, add in small increments 5. Replace the dipstick and tighten securely.
until the FULL mark is reached.
HURTH TRANSMISSION
6. It is normal, after the engine is turned OFF, for
the level to read above the FULL mark. SHIFT LEVER

PCM 1.23:1 TRANSMISSION

SHIFT LEVER
DIPSTICK

DIPSTICK

MIN. MAX

FULL MARK
Figure 11-3 Transmission Dipstick and Location

Figure 11-2 Transmission Dipstick and Location

L510010-09
30
 ENGINE MAINTENANCE - 11
PCM Power-Plus V-Drive Transmission LUBRICATION

WARNING Throttle Cable

Do not attempt to remove the transmission drain/ Lubricate pivot points and exposed cable (Figure 11-5)
fill plug while the engine is running or while the with SAE 30W-30 engine oil.
transmission is hot. Hot transmission fluid could be
sprayed from the hole.
BALL JOINT
All PCM Power-Plus “V” Drive transmissions are
designed to be ‘Maintenance Free’. Inspect fluid
CABLE
level after the first 25 hours of use and annually CLIP
thereafter. Fluid should only be changed if evidence
of contamination is present. Use Mobiltrans SHC 50
synthetic transmission lubricant. PCM P/N: R190250.
1. Remove the drain/fill/dipstick plug from the
transmission. Wipe the dipstick clean and insert
into transmission - Do Not Screw the dipstick into
the hole. Remove and observe the fluid level.
2. The fluid level should be between the FULL
mark and the end of the dipstick. If a plug is
used, fluid level should be to the bottom of LUBRICATION
the threaded hole. If low, add the specified fluid POINTS
through the threaded hole to the proper level.
NOTE: The transmission fluid is a very high viscosity, to Figure 11-5 Typical Throttle Cable
make adding fluid easier, remove both fill plugs.
Shift Cable
3. Replace the drain/fill/dipstick plug(s) and tighten
securely. Lubricate pivot points and exposed cable (Figure 11-6)
with SAE 30W-30 engine oil.

R041091 OR

FULL

LOW

LUBRICATION
Oil Fill/Drain Oil Fill/Drain POINTS
Plug Plug

PLEASURECRAFT
ENGINE GROUP
POWER PLUS
1.48
RATIO

MADE IN USA

Figure 11-6 Typical Shift Cable

Raw Water
Drain Plug

Figure 11-4 Transmission Service Location

L510010-09
31
ENGINE MAINTENANCE - 11
ELECTRICAL SYSTEM RELAY AND FUSE
BLOCK
MAIN PANEL FUSE
PCM engines are equipped with a 40 Amp PANEL fuse
which provides electrical overload protection for the
boat’s instrumentation wiring and components. Should
an electrical overload occur, the PANEL fuse will open
and prevent electrical current flow.
When this fuse opens, the cause for the high current
draw must be found and corrected. Check the battery
and alternator connections and all other harness
connectors between the boat and the engine main
harness. Check for loose or disconnected lead wires
and shorted circuits. Replace the PANEL fuse and
resume operation. If the cause of the overload cannot
be found, consult an authorized PCM Engines dealer to
make necessary repairs.
ELECTRICAL SYSTEM FUSES
PCM engines utilize fuses to protect critical engine 20 20
components and devices. The fuel pump, ECM, ignition
20 15
components, fuel injectors, starter and diagnostic
devices are protected by fuses. The fuse block is 40 5 15
mounted on a bracket near the rear of the engine.
BOAT’S IGNITION FUSE
If the engine will not crank when the ignition key is
turned to the START position, first check that the shift
lever is in the neutral position and the safety lanyard
(if equipped) is attached properly. If none of the Fuse
Block fuses are open, check for a blown boat ignition
fuse. The boat’s ignition fuse may be located on the
instrument panel, the fuse holder block or as part of
the helm’s instrument wiring harness. Check the wiring
diagrams supplied from the boat manufacturer for the
exact location.

ELECTRICAL SYSTEM WIRING AND

CONNECTORS
The electrical system wiring and connectors should be Figure 11-7 (Typical) Electrical System Relay and Fuse
checked periodically for loose or dirty connections and Block
damaged wiring. If electrical components or wiring show
signs of corrosion, deterioration or damage, consult an
authorized PCM Engines dealer to make necessary
repairs.

L510010-09
32
 ENGINE MAINTENANCE - 11
BATTERY Follow maintenance instructions and warnings as
supplied by the battery manufacturer. If this information
WARNING is not available, follow these guidelines for the proper
battery care.
Battery electrolyte is a corrosive acid and should
be handled with care. If electrolyte is spilled or • Do not operate the engine with an open in the
splashed on any part of the body, IMMEDIATELY battery circuit, as this may cause damage to the
flush the exposed area with liberal amounts of water alternator. Make sure that all connections are
and obtain medical aid as soon as possible. Safety clean and secure.
glasses and rubber gloves are recommended when
handling batteries or filling with electrolyte. • When removing the battery cables, always
remove the negative (-) cable first, and then
remove the positive (+) cable. When installing
battery cables, install the positive (+) cable first,
then install the negative (-) cable.

• Periodically check the battery for signs of

WARNING
corrosion, frayed battery leads or cracked case.
Hydrogen gases that escape from the battery when Repair or replace as necessary.
charging are highly explosive. Do not use jumper
cables and a booster battery to start the engine. Do • Periodically check the electrolyte level. Add
not recharge a weak battery in the boat. Remove distilled water to bring up to the proper levels.
the battery from the boat and recharge in a well
ventilated area away from fuel vapors, sparks and IMPORTANT: Your engine is designed to work with
open flames. the standard electronics installed in your boat. If you
add other electrical components or accessories, you
could change the way the fuel injection controls your
engine or the overall electrical system functions. Before
adding electrical equipment, consult your dealer. If you
don’t, your engine may not perform properly.

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

L510010-09
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ENGINE MAINTENANCE - 11
FRESH-WATER COOLING SYSTEM
HEAT EXCHANGER
SACRIFICIAL ZINC ANODE PROTECTIVE ANODE ZINC
Remove and check condition of zinc pencil
every 30 days. Replace if more than 50%
ANODE
missing with Crusader Part #10972.

Located in the raw water side of the heat exchanger is P/N 23627

a zinc anode which is marked by a decal. To check,

remove the plug and visually check the condition of
the zinc rod. The length of the zinc rod when new is
approximately 1.5 inches. If more than one half of the
zinc is gone, replace with a new zinc anode.

Different geographic locations and water make-up can

result in either high or low sacrificial requirements. A
high rate of zinc anode consumption should also alert
the owner to a possibility of an improperly wired boat
accessory, which would require complete checking by
qualified service personnel.

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

Exchanger (6.0L)

L510010-09
34
 ENGINE MAINTENANCE - 11
CHECKING COOLANT LEVEL

WARNING PRESSURE
DEGAS CAP
Do not remove cooling system filler cap when BOTTLE
the engine is hot. Allow the engine to cool and
then remove the pressure cap slowly, allowing the
pressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns.

Degas Bottle

The “see-through” degas bottle is connected to the

heat exchanger by a small hose. The degas bottle
collects coolant that expands with rising temperature,
and would otherwise overflow from the system. Coolant
level should be at or slightly above the “ADD” mark on
the bottle when the system is cold. Coolant should be
added ONLY to the bottle when the system cools. Add Figure 11-9 Checking Coolant Level (6.0L)
specified coolant as required.

L510010-09
35
ENGINE MAINTENANCE - 11
FLUSHING COOLING SYSTEM - SEA-WATER
SECTION

To prevent silt and/or salt build-up in the cooling system

(fresh or raw-water cooled), flush the sea-water section
of the cooling system with fresh water at specified
intervals. Close seacock (if applicable) before removing
inlet hose.

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

ATTACH
FLUSHING
CAUTION ADAPTER
HERE
Do not run the engine above 1500 RPM when
flushing. Suction created by the sea-water pump Figure 11-10 Typical Sea-Water Inlet
may collapse the flushing hose, causing the engine
to overheat. Watch the temperature gauge while
flushing to ensure the engine does not overheat.

L510010-09
36
 ENGINE MAINTENANCE - 11
TESTING COOLANT FOR ALKALINITY
WARNING
It is recommended that the coolant in the fresh-water
section be tested each year for alkalinity. Coolant Do not remove cooling system filler cap when
that is not alkaline has lost the effectiveness of its rust the engine is hot. Allow the engine to cool and
inhibitors, which can lead to internal corrosion and then remove the pressure cap slowly, allowing the
cooling system problems. It is recommended to replace pressure to vent. Hot coolant, under pressure, may
standard ethylene glycol coolant in the system every two discharge violently and cause severe burns.
years or long life coolant, Dex-Cool™, every five years
to prevent a build-up of harmful chemicals within the DRAINING FRESH-WATER COOLING SYSTEM
fresh-water system.
NOTICE: To protect the environment, dispose of
coolant properly. Check your local restrictions for proper
WARNING disposal instructions of removed coolant.
Do not remove cooling system filler cap when
NOTICE: Refer to cooling system water flow diagrams
the engine is hot. Allow the engine to cool and
then remove the pressure cap slowly, allowing the for drain locations.
pressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns. 1. Remove the following drain plugs to drain coolant
from the fresh-water cooling system:
1. Obtain red litmus paper from a local supplier
(drugstore, laboratory, etc.). − Drain plug on heat exchanger

2. Remove the pressure cap from the coolant filler − Remove the large hose from the engine
neck and insert one end of the litmus paper into block water circulating pump, or drain plug as
the coolant. shown in Figure 11-11.

3. If red litmus paper turns blue, coolant is alkaline − Drain plugs on the cylinder block (one on
and does not need to be replaced. If the litmus each side)
paper remains red, the coolant is not alkaline and
must be replaced. 2. Remove the following drain plugs to raw water
from the fresh-water cooling system:

− Drain plug on oil cooler

− Drain plug on heat exchanger

− Drain plug on the bottom of each exhaust

manifold

3. After system has drained completely, coat all the

drain plugs with PerfectSeal (or equivalent) and
reinstall in the proper locations. Reinstall the
hose(s) on the water circulating pump and tighten
the clamps securely.

Remove DRAIN PLUG

(as equipped)

Figure 11-11 Draining Engine Circulating Pump

(5.0/5.7L)

L510010-09
37
ENGINE MAINTENANCE - 11
FILLING FRESH-WATER COOLING SYSTEM
A new extended life engine coolant known as DEX- ANTIFREEZE
COOL™ is used in your engine(s). It is imperative to SOLUTION
note the following about DEX-COOL™ engine coolant:
• IT IS PINK IN COLOR TO DISTINGUISH IT
FROM CONVENTIONAL COOLANT.
• THE SERVICE CHANGE INTERVAL ON
ENGINES BUILT WITH DEX-COOL™ IS 5
YEARS.
• TO MAINTAIN FULL CORROSION
PROTECTION DURABILITY, DEX-COOL™
MUST NOT BE MIXED WITH CONVENTIONAL
(CONTAINING SILICATE) ENGINE COOLANTS.
• DEX-COOL™ IS AN ETHYLENE GLYCOL
BASED PRODUCT, THEREFORE, BOIL AND
FREEZE PROTECTION ARE MEASURED IN
THE SAME FASHION AS CONVENTIONAL Figure 11-12 Filling F.W.C. System (6.0L)
COOLANTS.
TO FULLY REALIZE ITS MANY ADVANTAGES,
DEX-COOL™ MUST NEVER BE MIXED WITH
CONVENTIONAL COOLANTS.
DEX-COOL™ can become contaminated by
inadvertently topping-off with conventional coolant,
adding conventional coolant to the system or even if
fill/drain containers are shared between coolants. If
contamination occurs, the cooling system must be
immediately drained and flushed, and refilled with DEX-
COOL™. No short-term damage will occur, however,
the service interval will be reduced from 5 years to 2
years.
The fresh-water cooling side of the cooling system
must be filled with a 50/50 mixture of DEX-COOL™
(or equivalent, which meets GM6277M) extended life
antifreeze and water solution.
IMPORTANT: More than 50% antifreeze solution can
contribute to an overheating condition.
IMPORTANT: If the engine is being placed in winter
storage, the fresh-water cooling section must be filled
with a correct type of coolant and water solution,
properly mixed, to protect the engine to the lowest
temperature to which it will be exposed.
1. Make sure that all drain plugs are properly
installed.
2. Remove the pressure cap. Fill the system with
antifreeze solution until the system is filled.
See ENGINE FLUID CAPACITIES for system
capacities.
3. Start the engine and operate at idle speed (1200-
1500 RPM) to purge any air from the system.
When the system is full, install the pressure cap.

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 ENGINE MAINTENANCE - 11
CLEANING SEA-WATER SECTION OF HEAT
EXCHANGER - FRESH-WATER COOLED
MODELS ONLY

The sea-water section of the heat exchanger should HEAT

be cleaned whenever there is a noticeable decrease in EXCHANGER
cooling efficiency. You may use the following procedure
for cleaning, or, if the build-up of scale and mineral
deposits is heavy, it is recommended that the heat
exchanger be removed and taken to a repair facility to be
boiled out (such as a radiator repair facility).
PLATE
1. Remove the bolts securing the heat exchanger
end plates. Remove the end plates and gaskets.
COOLANT
2. Clean the water passages in the heat exchanger DRAIN PLUG
by inserting a suitable-size wire brush into each
passage. Use compressed air to blow out loose BOLT
particles. RAW WATER GASKET
DRAIN PLUG
3. Clean the gasket surfaces on the end plates and
the heat exchanger. Apply PerfectSeal to both
sides of the new gaskets. Install the end plates Figure 11-13 Heat Exchanger and End Plate Removal
and the new gaskets onto the heat exchanger. (Typical)
Install the bolts and tighten securely.

4. Start the engine and inspect for leaks.

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ENGINE MAINTENANCE - 11
FUEL SYSTEM DESCRIPTION Fuel Control Cell (FCC) Fuel System
The Fuel Control Cell (FCC) eliminates vapor lock and
WARNING air ingestion caused by fuel tank slosh, and provides the
necessary filtration and water separation.
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline The FCC system incorporates two (2) fuel pumps to
is extremely flammable and highly explosive under provide an uninterrupted flow of fuel to your PCM marine
certain conditions. Be sure the ignition key is off and engine. Fuel is fed into the FCC bowl by a low-pressure,
do not smoke or allow open flame in the area while high-volume electric fuel pump. This pump flows fuel at
servicing. Wipe up any spilled fuel immediately. a volume much greater than the fuel flow rate required of
the high-pressure pump and engine demands. The high-
pressure pump, mounted inside the FCC bowl, provides
the necessary fuel pressure and volume to maintain
proper engine performance. The FCC constantly has
WARNING an ample supply of fuel to meet the idle, cruise and
acceleration fuel requirements of the engine.
Accumulation of water and other fuel contaminants
The fuel pressure regulator may be located on the fuel
may form corrosive compounds that can damage
rail or inside the FCC bowl, controls the fuel pressure
the fuel filter, and result in fuel leakage. Ethanol
and maintains a constant pressure across the fuel
blended fuel may increase this risk. For this reason,
delivery system. Excess fuel, not used by the engine,
annual replacement of the fuel filter, at a minimum, is
returns to the FCC bowl.
required to avoid risk of explosion or fire.
The fuel delivered to the engine by the FCC is filtered
by a filter and water separator element, which surrounds
the high pressure pump inside the FCC bowl.
As indicated above, fuel enters the FCC bowl from
WARNING two (2) locations, the low-pressure pump (initial input)
and the fuel pressure regulator (unused, recirculating
Extreme caution must be exercised when servicing
fuel). Fuel exits the FCC bowl at two (2) locations, the
the fuel system. The fuel system operates under
high-pressure output to the fuel injection system and all
high pressure. Use caution when removing or
excess fuel in the FCC bowl is routed back to the tank
replacing components, as residual pressure may be
via the return line.
present.

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

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

L510010-09
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 ENGINE MAINTENANCE - 11

FUEL
SUPPLY
LINE

FUEL
RETURN
LINE
5.0/5.7L RETURN
ONLY TO
FUEL
FUEL
CONTROL
TANK
CELL

FROM
FUEL
TANK
LOW-PRESSURE
FUEL PUMP

OUT IN

PN: R080024A

PRIMARY
FUEL
FILTER

Figure 11-14 Fuel Control Cell (FCC) Fuel System (Typical)

Servicing the FCC Primary Fuel Filter (FCC Clamp-on Canister)
The frequency of draining the water or replacing the filter
element is determined by the contamination level of the WARNING
fuel. Replace the filter element at least once a year, or
when a loss of power is noticed (whichever occurs first). Extreme caution must be exercised when servicing
the fuel system. The fuel system operates under
high pressure. Use caution when removing or
WARNING replacing components, as residual pressure may be
present.
Improper use, installation or servicing may cause an
explosion or fire resulting in bodily injury, or death. Draining the FCC Bowl, ENGINE OFF
This unit should only be serviced by a qualified 1. Disconnect the two-wire electrical connectors
technician. Read and follow all instructions before from the FCC and the Low Pressure Fuel Pump
proceeding. Run the engine and check for fuel leaks (LPFP).
after installation, element replacement or draining 2. Remove the 7/16” plug, and drain the bowl
the bowl. DO NOT remove the FCC bowl unless contents into an approved container.
servicing the filter element, otherwise contamination
or bowl O-ring swelling may result. CAUTION: Both fuel and water will drain from the
FCC bowl.
3. Apply pipe sealant, suitable for use with gasoline,
to the threads of the 7/16” plug.

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ENGINE MAINTENANCE - 11
4. Tighten the 7/16” plug.
5. Reconnect the two-wire electrical connectors to
the FCC and LPFP. 6.0L 5.0/5.7L

6. Cycle the ignition key several times to run the OR

electric fuel pumps and fill the FCC bowl with

fuel. Inspect the drain plug area for leaks. O-RINGS

Correct any leaks prior to operating the engine. FUEL

PRESSURE
REGULATOR

7. Start the engine and inspect for fuel leaks.

Correct any leaks prior to operating the engine
any further.
Filter Element Replacement, ENGINE OFF
FCC SERVICE KIT#: RP080026 FUEL
PUMP

1. Disconnect the two-wire electrical connectors

from the FCC and the Low Pressure Fuel Pump FUEL
FILTER
(LPFP).
2. Disconnect the fuel supply line from the LPFP.
RETAINING
WARNING CLAMP

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

3. Remove the 7/16” plug, and drain the bowl

contents into an approved container. Figure 11-15 Fuel Control Cell (FCC) - Clamp-on
CAUTION: Both fuel and water will drain from the Canister (Typical)
FCC bowl. 10. Install the new O-rings in the same location.
4 Remove the canister retaining clamp. Lubricate the new O-rings with a fuel resistant
O-ring lubricant.
5 Slide the canister downward over the suspended
filter element. It may be necessary to pull the 11. Apply pipe sealant, suitable for use with gasoline,
unit to one side in order to remove. to the threads of the 7/16” plug.
6. Remove the fuel filter element from the 12. Install and tighten the 7/16” plug into the canister.
suspended pump by gripping the fuel pump 13. Install the canister firmly back onto the FCC
with one hand, and pulling the filter element head.
downward with the other hand.
14. Reinstall the retaining clamp and tighten
7. Visually inspect all internal components, i.e. securely.
hoses, wires, etc.
15. Reconnect the fuel supply line to the LPFP.
8. Push on new filter element (part number
16. Reconnect the two-wire electrical connectors to
RP080026) over the electric fuel pump.
the FCC and the LPFP.
9. Using a pick made of soft material, such as a
17. Cycle the ignition key several times to run the
toothpick, remove the old O-rings from the FCC
electric fuel pumps and fill the FCC bowl with fuel.
head.
Inspect the drain plug area for leaks. Correct any leaks
CAUTION: The mounting head O-ring grooves may
prior to operating the engine.
be damaged by using sharp steel tools to remove
the O-rings. 18. Start the engine and inspect for fuel leaks.
Correct any leaks prior to operating the engine
CAUTION: Use only fuel approved O-rings
any further.
(R047241) provided in RP080026 Kit. Use of non-
approved O-rings may cause fuel to leak from the DO NOT ATTEMPT TO SERVICE ANY OTHER PARTS
FCC. ON THIS UNIT.

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 ENGINE MAINTENANCE - 11
Servicing the Primary Fuel Filter Priming Fuel System
The frequency of replacing the filter element is
To prime the fuel system, cycle the ignition key 3 times
determined by the contamination level of the fuel.
using the following procedures:
Replace the filter element at least once a year, or when
a loss of power is noticed (whichever occurs first).
1. Turn ignition key to ON position for 5 seconds.

WARNING 2. Turn ignition key OFF.

Improper use, installation or servicing may cause an 3. Pause for 10 seconds.

explosion or fire resulting in bodily injury, or death.
This unit should only be serviced by a qualified 4. Repeat steps 1-3 three times.
technician. Read and follow all instructions before
proceeding. Run the engine and check for fuel leaks Crank the engine until it starts or 30 seconds elapse. If
after installation or element replacement. the engine does not start, repeat the priming procedures.

Filter Element Replacement, ENGINE OFF FLAME ARRESTOR

PRIMARY FUEL FILTER #: R080024A At specified intervals, the flame arrestor should be
NOTE: This filter may be located in various locations. checked for blockage caused by dirt or other foreign
Consult your boat manufacturer’s operation manual for material.
correct location.
Loosen the fastener securing the flame arrestor to the air
1. Disconnect the fuel lines from the input and
intake throttle body. Remove the flame arrestor. Clean
output of the filter and block the lines to prevent
the flame arrestor with solvent and dry with compressed
fuel spillage.
air. Reinstall the flame arrestor and tighten the fastener
3. Remove the filter. securely.
5. Install the new filter. Ensure the new filter is
installed correctly. Input side of the filter is from
the fuel tank and output is to the engine.
7. Re-install the fuel lines and tighten the retaining FLAME
ARRESTOR
clamps securely.
8. Start the engine and inspect for fuel leaks.
Correct any leaks prior to operating the engine
any further.

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

THROTTLE
BODY

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

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ENGINE MAINTENANCE - 11
ACCESSORY DRIVE BELT SERVICING RAW WATER PUMP IMPELLER
PCM engines use a single serpentine belt to drive the IMPELLER KIT #: RP061022
engine water circulation pump, sea-water pump and the
The raw water pump impeller should be serviced every
alternator.
50 hours, or once a year, whichever occurs first. See
Maintenance Schedule.
WARNING
Locations “A” (Figures 11-17 / 11-19) are access holes
Engine must be shut OFF and the ignition key in order to loosen the raw water pump attaching bolts.
removed before inspecting the drive belt(s). The The bolts are secured in the pump by O-rings, and will
drive belt(s) should be checked periodically for not fall out during removal.
condition and tension. If the belt(s) shows signs of Torque the raw water pump housing attaching bolts
cracking, glazing or deterioration, replace with new to 8.5-9 ft.lbs. (11.5-12 N-M), when re-installing the
belt(s). impeller.
DRIVE BELT INSPECTION
Inspect the drive belt for excessive wear, shredding or
missing sections. Alternator

Inspect the drive belt for contamination from excessive

dirt, oil, coolant or other substances that may effect the
Idler
drive belt operation. Belt
Tensioner
If a problem is found, replace the belt after inspecting the
following items:
• All pulleys and tensioners for signs of
Circulation
misalignment Pump Raw Water
• All pulleys and tensioners for signs of rust or Pump
other damage
• Bent pulleys or tight bearings in the engine water
circulation pump, sea-water pump and alternator
DRIVE BELT REPLACEMENT Crankshaft
Pulley
5.0/5.7L (LH) SERPENTINE BELT #: R066028
6.0L SERPENTINE BELT #: R066033 A
1. Note the routing of the belt before removing.
2. Using a 15 mm box wrench or socket, turn the Figure 11-17 6.0L Accessory Drive Belt Configuration
belt tensioner to relieve the tension on the belt.
Slide the belt off of the pulleys. Release the
tensioner slowly to prevent the tensioner
from snapping against its stop, and possibly
causing damage to the tensioner.
3. Slide the new belt onto the pulleys using the
same routing as noted prior to removal.
4. Compress the belt tensioner, and slide the belt
over the tensioner pulley. Release the tension
slowly to tension the belt.

Figure 11-18 Belt Tensioner (6.0L)

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 ENGINE MAINTENANCE - 11

Belt
Tensioner

Circulation Raw Water

Pump Pump

Alternator

Crankshaft
Pulley

Figure 11-19 5.0/5.7L Accessory Drive Belt

Configuration

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

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ENGINE MAINTENANCE - 11
CHANGING OILS

WARNING
IMPORTANT: The Federal Water Pollution Control
Act prohibits the discharge of oil or oily waste into
or upon the navigable waters and continuous zone
of the United States, if such discharge causes a
film or sheen upon, or discoloration of the surface
of the water, or causes sludge or emulsion beneath
the surface of the water. Violators are subject to a
penalty of $5,000.00.
Refer to the MAINTENANCE SCHEDULE for oil change OIL QUICK-DRAIN
HOSE
intervals. The engine and transmission oils should be
changed prior to placing the boat into storage.
CONTAINER
The transmission oil change should be performed by an
authorized PCM Premier dealer, at specified intervals. Figure 11-21 Engine Oil Removal
Transmission fluids should be removed through a copper
tube, that extends to the bottom of the transmission
case, using a suction/vacuum type fluid extractor.
IMPORTANT: Change the engine oil when the OIL
engine is warm from operation. Warm oil flows FILL
more freely, and allows more foreign material and
impurities to be removed.
The engine oil filter is remote mounted. The engine
block location, where the filter is normally mounted,
is covered with an oil filter bypass adapter. DO NOT
remove this adapter when changing the oil.

CAUTION
DO NOT OVERFILL ENGINE CRANKCASE WITH
OIL. Excessive oil can lead to premature engine
component failure and/or loss of performance.
Figure 11-22 Engine Oil Fill (5.7L)
1. With the engine at normal operating temperature, cover (Figure 11-22). See OIL REQUIREMENTS
locate the oil pan quick drain hose and thread page 28 and ENGINE FLUID CAPACITIES page
the hose through the boat’s drain plug hole. 54, respectively.
(Figure 11-21). Remove the cap from the end
of the quick-drain hose and insert the discharge 5. Start the engine and operate for 5 minutes to
hose into a suitable container. Allow the oil from circulate the oil throughout the engine. Check
the engine to drain until the crankcase is empty. entire system for leaks, especially around the oil
Reinstall the cap onto the quick-drain hose and filter.
pull the hose back through the drain and secure 6. Stop the engine and wait 5 minutes to allow
the hose at the engine. the oil to completely drain down. Check the oil
2. Remove the oil filter by turning it level. Add or remove oil, as needed, to bring the
counterclockwise, using an oil filter wrench if engine oil to the proper level. See CHECKING
necessary. Discard the old filter and sealing ring. FLUID LEVELS page 29 for Important Notes and
Cautions to observe when checking the engine
3. Coat the sealing ring, on the new filter, with a crankcase oil level.
light coating of clean engine oil. Install the oil
filter securely by hand. DO NOT overtighten. IF YOU ARE UNSURE OF THE CORRECT AMOUNT
OF OIL TO USE DURING A SERVICE INTERVAL,
4. Fill the engine with the recommended oil and PERFORM THE FOLLOWING PROCEDURE:
quantity, through the oil fill location on the valve
(1) Drain the oil and change the oil filter.

L510010-09
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 ENGINE MAINTENANCE - 11
(2) Add four (4) quarts of new oil. The Transmission mounts may need to be adjusted so
(3) Start and run the engine allowing sufficient time for there is no tension on the mounting bolts as they are
the new oil to circulate and fill the new oil filter. re-installed. Re-tighten all trunnion bolts to complete the
V-Drive alignment.
(4) Shut the engine off. Wait 5 minutes to allow the oil
to completely drain back to the pan. Check the oil NOTE: Some PCM V-Drive configurations use
level with the dipstick and add the correct amount of only engine and transmission mounts. Alignment is
oil to fill to the “FULL” mark on the oil level dipstick. accomplished using those mounts.

ENGINE ALIGNMENT
ENGINE ALIGNMENT
IMPORTANT: Engine alignment MUST BE
RECHECKED with the boat in the water, fuel tanks full
CAUTION and with a normal load on the boat. Engine must be
Engine must be properly aligned, or vibration, noise aligned so that the transmission and the propeller shaft
and damage to the transmission output shaft, oil seal, coupling center lines are aligned, and coupling faces
and bearings may result. are parallel within 0.003 in. (0.07 mm). This applies
to installations with solid couplings, as well as flexible
IMPORTANT: For PCM Power-Plus V-Drive couplings.
applications, adjust the engine and V-Drive mounts
to achieve alignment. The Transmission mounts are 1. Check the mating surfaces on the transmission
for support only and, are not used to achieve proper and the propeller shaft couplings. Make sure
alignment. they are clean and flat (Figure 11-24).

PLEASURECRAFT
ENGINE GROUP
POWER PLUS
1.48
RATIO

MADE IN USA

Figure 11-23 PCM V-Drive

V-DRIVE ALIGNMENT Figure 11-24 Shaft Mating Surface Check

The Transmission support mounts must be removed 2. Center the propeller shaft in the shaft log as
before performing the engine alignment. Alignment is follows: (Figure 11-25)
achieved using the Engine front mounts and the PCM
V-Drive rear mounts. • Push down and then lift the propeller shaft as
far as it will move, then place the shaft in the
• Alignment with a PCM V-Drive: loosen the middle of the movement.
trunnion bolts on the TRANSMISSION mounts,
then remove the bolts used to attach the mount to • Move the shaft to the port and then to the
the Transmission. Slide the mount away from the starboard as far as the shaft will move,
transmission. then place the shaft in the middle of the
Perform the Engine Alignment as outline in the following movement.
steps. When you have completed the alignment you
will need to re-install the mounts onto the Transmission. • With the propeller shaft in the middle of the
shaft log, align the engine to the shaft.

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ENGINE MAINTENANCE - 11
.003 INCH
(0.07 mm)
FEELER GAUGE TRANSMISSION
OUTPUT FLANGE

A
PROPELLER
SHAFT
COUPLING
B FLANGE

A
STRAIGHT
EDGE

Figure 11-27 Angular Alignment

Figure 11-25 Centering Prop Shaft
3. Check that the coupling center lines align by OFFSET ALIGNMENT:
butting the propeller shaft coupling against 4. If the coupler center lines are not aligned, adjust
the transmission coupling (Figure 11-26). The the mounts as follows:
shoulder on the propeller shaft coupling face • UP or DOWN OFFSET ADJUSTMENT:
should engage the recess on the transmission Loosen the locking nut. Turn the adjusting
coupling face, with no resistance. nut or the adjusting bolt in the direction
required to raise or lower the engine. After
the adjustment is complete, tighten the
locking nut.

IMPORTANT: For Offset Alignment, both front mounts

(or rear mounts) must be turned equally or angular
misalignment will occur.
OFFSET ANGULAR
MISALIGNMENT MISALIGNMENT

LOCKING
NUT
PERFECT ALIGNMENT
COUPLING FACES ARE PARALLEL
WITH DISTANCE BETWEEN FACES
EXACTLY THE SAME AT ALL POINTS ADJUSTING
NUT
Figure 11-26 Shaft Mating Surface Check
IMPORTANT: Offset misalignment conditions must be
corrected prior to checking for angular misalignment.

NOTICE: Some propeller shaft couplings may not have

a shoulder on the mating surface. On these installations,
use a straight edge to check the centerline alignment
(Figure 11-27). Figure 11-28 Mount Adjustment

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 ENGINE MAINTENANCE - 11
• LEFT or RIGHT ADJUSTMENT: Loosen the
.003 INCH
trunnion clamping bolt and the nut on all
(0.07 mm)
four mounting brackets. Move the engine FEELER GAUGE TRANSMISSION
to the left or right, as necessary, to obtain OUTPUT FLANGE
the proper alignment. After adjustment is
complete, tighten all bolts.
PROPELLER
SHAFT
ADJUSTING COUPLING
LOCKING BOLT FLANGE
NUT

STRAIGHT
EDGE

Figure 11-31 Angular Alignment

5. Check for any angular misalignment. Hold

coupling faces tightly together by hand and check
for a gap between the coupling faces, with a
0.003 in. (0.07 mm) feeler gauge, at 90-degree
intervals. (Figure 11-31).
Figure 11-29 Mount Adjustment
IMPORTANT: The large diameter of the mount trunnion
A
MUST NOT extend over 1.750 in. (44.45 mm), from the
mounting brackets on any of the mounts; and a sufficient
amount of the trunnion must remain in the mount to be LC RC
secured by the trunnion locking bolt.
1.750 in. MAX
(44.45 mm)

B B

TRUNNION
BOLT

LC RC

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

Figure 11-30 Engine Extension

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ENGINE MAINTENANCE - 11
Angular Misalignment Front Mount Adjusted

A Both

B Trunnion

LC R

RC L

• To adjust a corner of the engine up or down,

loosen the locking nut. Turn the adjusting nut
or the adjusting bolt in the direction required
to raise or lower the engine. After the
adjustment is complete, tighten the locking
nut.

IMPORTANT: If a “pinch” occurs in the “A” quadrant

(Figure 11-32), correcting the condition will require
an equal adjustment on the front mounts. If a “pinch”
occurs in the “C” quadrant, an adjustment will be made
on the opposing front mount. If a “pinch” occurs in the
“B” quadrant, a trunnion adjustment is required.

• To move the engine left or right, loosen the

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

6. After the engine has been properly aligned,

secure the engine mounts.

7. Connect the propeller shaft coupling to the

transmission coupling. Tighten the coupling
attaching bolts and nuts to the correct
specifications.

FASTENER TORQUE SPECIFICATIONS

Location Lb-Ft (N.m)

Engine Mount to Stringer Securely

Propeller 50 (68)

Trunnion Bolts 45 (61)

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 ENGINE MAINTENANCE - 11
ENGINE MAINTENANCE LOG
Operating
Date Maintenance/Repair Hours

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ENGINE MAINTENANCE - 11
MAINTENANCE SCHEDULE

After 1st Every 50 Every 100

Location and Service Check 25 Hrs of Hours of Hours of Once
Daily Operation Operation Operation Each Year

Check coolant level - Fresh-water cooled

models only X

Check oil level - Engine crankcase X

Check oil level - Transmission X

Engine Assembly (complete - Check for

obvious leaks (water, oil, fuel and exhaust) X

Remote Control and Steering System -

Check for proper operation X

Sea Strainer - Check (if equipped) X

Cooling System - Check condition and

tightness of all hose clamps X X1 X

Cooling System - Inspect/Replace

raw water pump impeller X X

Drive Belt - Inspect condition and check

tension X X X

Exhaust System - Check condition and

tightness of all hose clamps X X1 X

Exhaust System - Check for water leaks at

the manifold, riser and elbow gaskets X

Ignition System and Spark Plugs - Clean

and inspect condition O O O

Engine Assembly (complete) - Check for

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

Change engine oil and filter X X X

Engine Alignment - Check and adjust if

necessary O O

Ignition Timing - Not Adjustable

Battery - Check electrolyte level and

specific gravity. Inspect case for damage.
Check cables and connections. X X X

Electrical System (complete) - Check for

loose or dirty connections and damaged
wiring X2 X

Flame Arrestor and Crankcase Ventilation

System - Clean and inspect X X

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 ENGINE MAINTENANCE - 11
MAINTENANCE SCHEDULE (cont’d)

After 1st Every 50 Every 100

Location and Service Check 25 Hrs of Hours of Hours of Once
Daily Operation Operation Operation Each Year

Hoses (all) - Inspect for cracks, swelling,

weather checking or other signs of
deterioration X X

Shift and Throttle Cable Linkage - Inspect

and lubricate (A) X1 X

Fuel Filters - Service or replace O O O

Transmission - Change fluid (B) and clean

strainer, if equipped O O

‘V’-Drive Transmissions - Change fluid (C)

and clean strainer, if equipped O O

MAINTENANCE SCHEDULE (cont’d)

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

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

Fresh-water cooled models - Change coolant Every five years

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

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

Cooling System (SALT WATER AREAS ONLY) - Flush

sea-water section After use each day (X)
Notes: (D) Use WD-40 penetration oil or equivalent
(X) Denotes service to be performed by the owner/ 1 In fresh-water areas, every 100 hours of operation or
operator 120 days (whichever occurs first). In salt-water areas,
(O) Denotes service to be performed by an authorized every 50 hours of operation or 60 days (whichever
PCM Engines Premier dealer occurs first).
(A) Use SAE 30 engine oil 2 In fresh-water areas, every 50 hours of operation or
(B) All PCM, Velvet Drive and Hurth transmissions - Use 60 days (whichever occurs first). In salt-water areas,
Dexron III automatic transmission fluid every 25 hours of operation or 30 days (whichever
(C) All PCM Power-Plus “V” Drive transmissions are occurs first).
designed to be ‘Maintenance Free’. Inspect fluid
3 Requires more frequent inspection if used in extremely
level after the first 25 hours of use and annually
thereafter. Fluid should only be changed if evidence salty, polluted or mineral-laden waters.
of contamination is present. Use Mobiltrans SHC
4 See COOLANT SPECIFICATIONS.
50 synthetic transmission lubricant. PCM P/N:
R190250 PCM Engines recommends that all periodical and annual
All Walters “V” Drive transmissions - Use Exxon service be performed by your local, authorized PCM
Spartan EP-68 or SAE 30 engine oil Engines Premier dealer.
All Velvet “V” Drive transmissions - Use Dexron III
automatic transmission fluid

L510010-09
53
ENGINE MAINTENANCE - 11
VISUAL INSPECTION Touch up scratches, nicks and corrosion damage to
the exterior finish of the engine. Spray paint may be
It is important for the owner/operator to visually inspect obtained from your local PCM Engines dealer.
the complete engine assembly at regular intervals. Most
often, costly repairs can be avoided if potential problems Protect engine finish from corrosion by periodically
are corrected before there is a failure. spraying the engine exterior finish with a rust
preventative oil (such as WD-40).
Inspect the complete engine assembly for obvious fuel,
oil, water or exhaust leaks. Check for loose, damaged
or missing parts. Check all hose clamps for adequate
tightness. Check the electrical system for loose or dirty
connections or damaged wiring.

ENGINE FLUID CAPACITIES

Model MP 5.0L / 5.7L MP 6.0L CES 6.0L

Crankcase Oil Capacity

W / NEW FILTER 4.75 Quarts (4.5 L)1 5 Quarts (4.73 L)1 5 Quarts (4.73 L)1

Fresh Water Cooling

System Capacity 18 Quarts (17.03 L) 18 Quarts (17.03 L) 23 Quarts (21.85 L)

TRANSMISSION FLUID CAPACITIES

Model All Models Type

PCM, 1:1 Ratio 1,2 2.0 Quarts (1.9 L) DEXRON III

PCM, 1.23:1 Ratio 1,2 2.0 Quarts (1.9 L) DEXRON III

Hurth (Exc. V-Drive), All Ratios 1,2 4.0 Quarts (3.79 L) DEXRON III

Hurth V-Drive, All Ratios 1,2 4.5 - 5.0 Quarts (4.26 - 4.73 L) DEXRON III
Mobiltrans SHC 50
PCM Power-Plus V-Drive, All Ratios 1,2 1.5 Quarts (1.42 L) synthetic - R190250

ZF 2-Speed 90 IVTS 1.5:1 Ratio 1,2 4.8 Quarts (4.5 L) DEXRON III

Walters RV-36D V-Drive 1.5 Quarts (1.42 L) SAE 30

1 - Engine Fluid Capacities are dependent on installation angle. DO NOT overfill the crankcase or
transmission. Remove excess fluid above the “FULL” mark on the dipstick. Check oil with the boat at its
normal, level, at rest position on the water. Ensure that ballast systems (if equipped) and excess water in
the bilge have been purged. If the boat is on a trailer, the trailer must be level and adjusted to represent
the boat’s normal resting state on the water. Oil capacities are approximate, and may not include capacity
needed for transmission cooler and oil lines. Refer to the Checking Fluid Levels instructions page 29 and
Changing Oils instructions page 46, of this manual, for complete instructions, important notes and Cautions
for checking engine oil levels. Always use the dipstick to determine the exact quantity of oil required. Add
the correct amount of oil to fill to the “FULL” mark on the oil level dipstick.
2 - Refer to the Checking Fluid Levels instructions pages 30-31 of this manual for complete instructions for
checking transmission fluid levels. IMPORTANT: Fluid levels on the PCM 1:1 and 1.23:1 transmissions
are checked while the engine is running. All other transmission fluid levels are checked at operating
temperature and immediately after shutdown of the engine.

L510010-09
54
 ENGINE MAINTENANCE - 11
FILTER REQUIREMENTS
Description Part No.

Oil Filter (remote-mounted) R077001

Kit, Transmission Oil Filter (ZF) RP077011

Primary Fuel Filter R080024A

Fuel Control Cell (FCC) Fuel Filter Element RP080026

OUT IN

PN: R080024A

RP080026

PCM POWER-PLUS V-DRIVE LUBRICANT

Description Part No.

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

PCM BASIC CRUISE SPEED CONTROL SYSTEM

Description Part No.

PCM Basic Cruise Control Panel RA152008

Speed Control Interface Harness - 14 Ft RA121091B

L510010-09
55
ENGINE SPECIFICATIONS - 12
PCM MASTER ENGINE SPECIFICATIONS - 2009
MODEL CES/MP 5.0L CES/MP 5.7L CES/MP 6.0L
(Horsepower) (275 HP) (343 HP) (409HP)

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

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

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

Compression Ratio 9.4:1 9.4:1 9.67:1

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

WOT Operating RPM 4600-5000 (**5100) 4800 - 5200 (**5300) 5200 - 5600 (**5600)
Preferred WOT RPM 4800 5000 5500

Cruising RPM (Max) 3800 4000 4000

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

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

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

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

Spark Plug P/N R030010 R030010 R030011

Spark Plug Gap 0.060 in. 0.060 in. 0.040 in.

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

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

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

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

Over- Temperature 200° F (93.3° C) 200° F (93.3° C) 200° F (93.3° C)

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

Alternator Rating 100 Amps 100 Amps 100 Amps

Ignition Timing Not Adjustable Not Adjustable Not Adjustable

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

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

L510010-09
56
 PCM MASTER FUEL PRESSURE SPECIFICATIONS - 2009
ALL ALL ALL
MODEL 5.0L 5.7L 6.0L

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

STD. FCC

Fuel Pressure - FCC 57-62 psi

Returnless to Rail (WOT)

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

ALL ENGINES (WOT) (WOT) (WOT)

IMPORTANT: FUEL PRESSURE MEASUREMENT MUST BE MADE WITH THE

ENGINE UNDER LOAD.

PCM MASTER WARNING/ALARM SPECIFICATIONS - 2009

MODEL 5.0L / 5.7L / 6.0L ALL CES Engines

Coolant > 200° F (93.3° C) Stage 1 Over-Temp, Sets - DTC 116, > 200° F (93.3° C) Stage 1 Over-Temp, Sets - DTC 116,
Over-Temperature Lights Malfunction Indicator Lamp (MIL), and/or sounds Buzzer Lights CGL and sounds Buzzer
Sensor > 210° F (98.9° C) Stage 2 Over-Temp, Sets - DTC 217, > 210° F (98.9° C) Stage 2 Over-Temp, Sets - DTC 217,
Lights MIL, and/or sounds Buzzer Lights CGL and sounds Buzzer, Low Rev Limit (~900 RPM)

L510010-09
Exhaust Gas Temp (EGT) 248° F ± 5° F, Sets - EGT Fault - DTC 2428, > 225° F (112.8° C) Stage 1, EMWT Fault - DTC 1415 / 1416,
Exhaust Manifold Water Lights Malfunction Indicator Lamp (MIL), and/or sounds Buzzer Lights CGL and sounds Buzzer, Low Rev Limit (~900 RPM)
Temperature (EMWT) > 250° F (118.3° C) Stage 2, EMWT Fault - DTC 1417 / 1418,
Over-Temperature Faults Lights CGL and sounds Buzzer, Engine Shutdown

Low Oil < 5 psi @ Idle RPM or < 24 psi @ 4000 RPM, < 5 psi @ Idle RPM or < 24 psi @ 4000 RPM,
Pressure Sensor Lights Malfunction Indicator Lamp (MIL), and/or sounds Buzzer Sets - DTC 524,
Lights Check Gauges Lamp and sounds Buzzer

Engine Specs
06/09

57
ENGINE SPECIFICATIONS - 12
ENGINE SPECIFICATIONS - 12
5.0 / 5.7 Liter 6.0 Liter
LH ROTATION LH ROTATION
FRONT FRONT

1 2 1 2

3 4 3 4

5 6 5 6

7 8 7 8
8

NO
2

DISTRIBUTOR
1

4
7

6
3

c
5

Rotation

FLYWHEEL END OF ENGINE

ALL V-8 MODELS

FIRING ORDER: FIRING ORDER:

1-8-4-3-6-5-7-2 1-8-7-2-6-5-4-3
Figure 12-1 V-8 Firing Orders

TUNE-UP SPECIFICATIONS
MP/CES 5.0L (275 HP) 6.0L
Model
MP/CES 5.7L (343 HP) All ZR409

Spark Plug Type R030010 R030011

0.060 in. 0.040 in.

Spark Plug Gap
(1.52 mm) (1.02 mm)

Fixed, Fixed,
Ignition Timing
Not Adjustable Not Adjustable

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

CAM Retard 15 + 2 degrees Not Adjustable

L510010-09
58
 OUT-OF-SEASON STORAGE - 13
ENGINE STORAGE
WARNING
IMPORTANT: This service should be performed by
an Authorized PCM Premier dealer. Operate the bilge blower and be sure no fuel vapors
are present when treating the engine. Be sure the
engine compartment is well-ventilated to prevent a
CAUTION potential fire hazard.

Refer to FLUSHING COOLING SYSTEM before 5. Restart the engine and allow it to idle for 5
proceeding. minutes.
. 6. Turn off the ignition and remove the spark plugs.
1. Fill the fuel tanks with gasoline and add a Use an aerosol-type fogging solution and spray
sufficient amount of gasoline stabilizer, such a sufficient amount of oil into each cylinder.
as STA-BIL™ fuel stabilizer, to prevent the (Follow the instructions for the storage oil used.)
formation of fuel gum and varnish. Follow the Turn the crankshaft several revolutions by hand
instructions on the container. to spread the oil evenly throughout the cylinders.

WARNING CAUTION

On fuel injected engines, you MUST bleed off fuel Excess storage oil in the engine’s cylinders can
pressure before proceeding. Failure to do so cause hydrostatic locking to occur, and severe
may cause personal injury. damage to the engine.
7. Install the spark plugs and connect the spark
2. Remove, empty and clean the fuel filter
plug wires.
assembly. Reinstall with a new fuel filter and
gasket / seals. Refer to Engine Maintenance for 8. Remove and clean the flame arrestor and
filter replacement procedures. the vent hoses, and reinstall on the engine.
Cover the throttle body assembly ,to prevent
NOTE: DO NOT re-use old fuel filter components.
the possibility of the water entering the engine
Always replace with new fuel filter element and gasket /
through the throttle body assembly, during
seals.
storage.
9. Close the fuel shut-off valve (if equipped).
WARNING
Accumulation of water and other fuel
contaminants may form corrosive compounds
that can damage the fuel filter, and result in fuel
leakage. Ethanol blended fuel may increase this
risk. For this reason, annual replacement of the
fuel filter, at a minimum, is required to avoid risk
of explosion or fire.

WARNING
Operate the bilge blower and be sure no fuel vapors
are present when treating the engine. Be sure the
engine compartment is well-ventilated to prevent a
potential fire hazard.
3. Run the engine and allow it to reach normal
operating temperature (a minimum of 10
minutes). Shut down the engine and change the
oil and oil filter (See ENGINE MAINTENANCE).
4. Flush the cooling system if operating in salt
water or brackish water areas. (See ENGINE
MAINTENANCE).

L510010-09
59
OUT-OF-SEASON STORAGE - 13
DRAINING INSTRUCTIONS
IMPORTANT: These services should be performed
by an Authorized PCM Premier dealer.

CAUTION
If the boat is to remain in the water during or after
draining, close the seacock to prevent a siphoning
action that may occur, allowing sea water to flow from
drain holes or removed hoses.
IMPORTANT: When removing the drain plugs, insert a
wire into the hole to remove any obstruction which would
prevent water from draining completely.
RAW-WATER COOLED MODELS
1. Remove all the drain plugs from the following
locations:
• Cylinder Block - one on each side (5.0/5.7L
Remove DRAIN PLUG
engines, remove the knock sensor on the port (as equipped)
and starboard sides). When installing the
knock sensor, torque to 20 N.m (15 lb ft).
Figure 13-1 Draining Engine Circulating Pump (5.0/5.7L)
• Exhaust Manifolds - remove hoses and/or
drain plugs, one on each side.
• CES 5.0/5.7L - remove drain plugs, one on
each side, exhaust corners.
• Transmission Cooler - one drain plug.
• (If Equipped) PCM V-Drive Transmission
- one drain plug.
PLEASURECRAFT
ENGINE GROUP
POWER PLUS
RATIO1.48
MADE IN USA

2. Remove the hose from the inlet side of the sea-

water pump.
3. Remove the large hose from the engine
circulating pump, or drain plug (if equipped).
NOTICE: It may be necessary to bend or lift the hoses
9/16”
to allow water to drain completely.
Hex Key
4. Remove the raw water pump impeller. (See Socket
ENGINE MAINTENANCE) If inspection proves or
the impeller to be in good condition, store it in 1/2”
Remove Raw Water
an accessible spot for re-installation at the end Drain Plug Square
of the storage period. A damaged or badly worn
impeller should be discarded and a new one Figure 13-2 Draining PCM V-Drive Transmission
installed at the end of the storage period.
NOTE: Removal of the impeller during storage will NOTICE: For additional protection against freezing and
prevent the impeller vanes from drying and taking a corrosion, you may wish to fill the engine with antifreeze.
permanent “set”. If ethylene glycol based antifreeze is used, check with
local environmental agencies about the proper disposal
5. After the water has completely drained, coat the
of antifreeze. It may be necessary to drain the system
threads of the drain plugs with PerfectSeal (or
prior to re-commissioning the boat.
equivalent), and reinstall in the proper locations.
Reinstall all the hoses and tighten the clamps 7. Remove the hoses which connect to the exhaust
securely. manifolds from the thermostat housing.
6. Loosen the engine alternator and raw water
pump drive belt(s).

L510010-09
60
 OUT-OF-SEASON STORAGE - 13
8. Remove the large circulating pump hose from • Transmission Cooler - one drain plug
the thermostat housing. Pour the mixture of • (If Equipped) PCM V-Drive Transmission
antifreeze and water, properly mixed to protect - one drain plug.
the engine to the lowest temperatures that it
will be exposed to, into the circulating pump 2. Remove the hose from the inlet side of the sea-
hose and fill the engine block. Pour additional water pump.
antifreeze solution into the hoses connected to 3. Remove the hose from the outlet side of the sea-
the exhaust manifolds. water pump.
NOTICE: It may be necessary to bend or lift the hoses
9. Reinstall the hoses into the thermostat housing
to allow water to drain completely.
and tighten the hose clamps securely.
4. Remove the raw water pump impeller. (See
After draining is completed, perform the additional ENGINE MAINTENANCE) If inspection proves
required maintenance as outlined in the MAINTENANCE the impeller to be in good condition, store it in
SCHEDULE under ONCE EACH YEAR. an accessible spot for re-installation at the end
of the storage period. A damaged or badly worn
DRAINING INSTRUCTIONS impeller should be discarded and a new one
installed at the end of the storage period.
CAUTION NOTE: Removal of the impeller during storage will
prevent the impeller vanes from drying and taking a
If the boat is to remain in the water during or after
permanent “set”.
draining, close the seacock to prevent a siphoning
action that may occur, allowing sea water to flow from 5. After the water has completely drained, coat
drain holes or removed hoses. the threads of drain plugs with PerfectSeal (or
equivalent), and reinstall in the proper locations.
IMPORTANT: When removing the drain plugs, insert a Reinstall the hoses and tighten all the clamps
wire into the hole to remove any obstruction which would securely.
prevent water from draining completely.
6. Loosen the engine alternator and raw water
pump drive belt(s).
FRESH-WATER COOLED MODELS
After draining is completed, perform the additional
IMPORTANT: The fresh-water section of the cooling required maintenance as outlined in the MAINTENANCE
system must be kept filled year around with SCHEDULE under ONCE EACH YEAR.
recommended coolant. Make certain that the cooling BATTERY STORAGE
system is protected with an ethylene glycol antifreeze
mixture properly mixed to protect the engine to the Follow the battery manufacturer’s instructions for
lowest temperature that it will be exposed to. storage. If not available, use the following instructions:
• Remove the battery from the boat and clean,
See the ENGINE MAINTENANCE section for testing removing dirt and grease from the top of the
alkalinity, draining and refilling procedures of the Fresh battery.
Water Cooling System, as required.
• Fill the battery with distilled water to the
manufacturer’s specifications.
IMPORTANT: Drain the sea-water section of the cooling
system only. • Store the battery in a cool, dry place. Do not
store on a concrete surface.
1. Remove all the drain plugs from the following
locations: • Periodically (every 30 to 45 days), check the
water level and recharge the battery to the
• Heat Exchanger - one on outboard side
manufacturer’s specifications. Do not fast
• **Exhaust Manifolds - remove hoses and/or charge.
drain plugs, one on each side
**IMPORTANT: DO NOT remove hoses or drain CAUTION
plugs from the exhaust manifolds of CES model
engines. These engines have Full Fresh Water A discharged battery can be damaged by freezing.
Cooling (antifreeze throughout the block and
manifolds).

L510010-09
61
OUT-OF-SEASON STORAGE - 13
RECOMMISSIONING AFTER STORAGE 8. Open the fuel shut-off valve (if equipped).

IMPORTANT: These services should be performed 9. Refer to the OPERATING INSTRUCTIONS

by an Authorized PCM Premier dealer. section and perform all the safety checks
before starting the engine.
When recommissioning the engine after storage, the
following items should be checked: 10. Refer to the Engine Maintenance section
and perform the Priming the Fuel System
1. Assemble the raw water pump and reinstall instructions.
on the engine.

2. Check all the cooling system hoses. Be sure

CAUTION
they are properly connected and all the hose If the engine(s) is (are) to be started prior to
clamps are tight. launching, use the procedure FLUSHING COOLING
SYSTEM before proceeding to start the engine(s).
CAUTION 11. Open the seacock before starting the engine.
When installing the battery, make certain that you
connect the POSITIVE (+) BATTERY CABLE to the 12. Start the engine and closely observe the
POSITIVE (+) BATTERY TERMINAL first, and the instrument panel. Allow the engine to reach
NEGATIVE (-) BATTERY CABLE to the NEGATIVE normal operating temperature. Inspect the
(-) BATTERY TERMINAL last. If the battery cables engine carefully for fuel, exhaust, oil and
are reversed, the electrical system will be damaged. water leaks.

13. Check the steering, shift and throttle controls

WARNING for proper operation.
Do not use jumper cables and/or a booster battery
to start the engine. Do not recharge a weak battery
in the boat. Remove the battery and recharge in a
ventilated area away from fuel vapors, sparks or open
flame.
3. Install the fully charged battery. Be sure
that all the connections are clean and free
from corrosion. Coat the battery terminal
connections with an anti-corrosion battery
terminal spray.

4. Readjust alternator and water pump drive belt

tension.

5. Check engine alignment.

6. Check engine and transmission oil levels.

7. Check engine mount fasteners.

L510010-09
62
 TROUBLESHOOTING - 14
Engine performance complaints usually fall under one of the basic headings listed in the Troubleshooting Guide. When
a problem cannot be easily diagnosed, consult a PCM Engines Servicing Dealer for assistance.

Malfunction Possible Cause Corrective Action

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

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

Remote control not in Neutral Position the remote control exactly

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

Dead Battery Recharge, test and replace as

necessary.

Engine Cranks - will not Improper starting procedure. Refer to “STARTING

start or is hard starting. ENGINE” in the OPERATING
INSTRUCTIONS section.

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

Engine flooded Open the throttle 100% and crank

the engine. When the engine starts,
immediately return the throttle to
1000 RPM.

Ignition system malfunction Contact PCM Engines Dealer.

Contaminated fuel Check fuel for water or other

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

L510010-09
63
TROUBLESHOOTING - 14
Malfunction Possible Cause Corrective Action

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

Collapsed, kinked or leaking Replace the hoses.

hoses.

Transmission/engine oil cooler Remove the water hoses and flush

plugged in opposite direction of the normal
flow.

Faulty thermostat Replace the thermostat.

Sea-water intake valve Open the valve completely.

partially/fully closed.

Restricted sea-water pickup Remove restriction.

Faulty temperature sending unit Test and replace as necessary.

or gauge

Sea-water pump impeller worn or Replace the impeller.

damaged

The following applies to engines Coolant level low in the fresh-water Check the cooling system for leaks.
equipped with Fresh-Water section of the cooling system Refill the system. See Warning
Cooling (FWC) systems. before removing the fill cap.

Heat exchanger passages plugged Clean and flush the exchanger.

with scales and debris

Improper coolant mixture Install the proper coolant mixture

(50% antifreeze - 50% water).

Insufficient engine temperature Faulty thermostat Replace the thermostat.

Faulty temperature sender Replace the temperature sender.

Engine oil pressure low Faulty oil pressure sending unit Test and replace as necessary.
or gauge

Oil level low Add specified oil. Check the engine

for leaks.

Crankcase overfilled causing oil Remove the required amount of oil.

aeration Determine the cause of overfilled
condition (improper filling, etc.).

Diluted or improper grade/ Change the oil and filter.

viscosity of oil Determine the cause of dilution.
(insufficient engine temperature,
excessive idling, etc.)

L510010-09
64
 TROUBLESHOOTING - 14
Malfunction Possible Cause Corrective Action

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

Transmission overfilled causing Drain required amount of oil.

oil aeration

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

Contaminated fluid Determine and correct the

contamination source and change
the fluid.

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

Plugged fuel filters Replace the fuel filters.

Faulty fuel pump. Have fuel pump replaced by a

PCM Engines Dealer/

Plugged or kinked fuel lines or Repair or replace the fuel lines.

fuel tank vent Remove obstruction.

Anti-siphon valve faulty Clean or replace as necessary.

Flame arrestor dirty Clean the flame arrestor.

Poor engine or boat Ignition malfunction Contact PCM Engines Dealer.

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

Damaged or improper propeller Repair or replace as necessary.

Excessive water in the bilge Pump the water out and investigate
source of entry.

Excessive growth on the boat Clean the bottom and paint with an
bottom anti-fouling paint.

Boat overloaded Reduce and/or redistribute the load.

Dirty flame arrestor Clean the flame arrestor.

Engine overheating Repair the cooling system (See

“Engine Overheats”).

L510010-09
65
66
1
WATER FLOW DIAGRAMS - 15

2
From Sea

L510010-09
Water Pickup

Note: This diagram is for illustration purposes

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

Figure 15-1 Direct Drive Raw-Water Cooling System (5.0/5.7L)

may vary slightly depending on installation.

= Drain Locations
 PCM V-Drive

PLEASURECRAFT
ENGINE GROUP
POWER PLUS
RATIO1.48
MADE IN USA

1/2”
Square

Raw Water
Drain Plug

L510010-09
1

2
From Sea
Water Pickup

Figure 15-2 Vee Drive Raw-Water Cooling System (5.0/5.7L)

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

67
= Drain Locations
WATER FLOW DIAGRAMS - 15
68
WATER FLOW DIAGRAMS - 15

L510010-09
From Sea
Water Pickup

Figure 15-3 Direct Drive Half System (5.0/5.7L)

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

PLEASURECRAFT
ENGINE GROUP
POWER PLUS
RATIO1.48
MADE IN USA

1/2”
Square

Raw Water
Drain Plug

L510010-09
Figure 15-4 Vee Drive Half System (5.0/5.7L)
From Sea
Water Pickup

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

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

69
on installation.
WATER FLOW DIAGRAMS - 15
70
1
WATER FLOW DIAGRAMS - 15

2 From Sea

L510010-09
Water Pickup

Figure 15-5 Direct Drive CES (5.0/5.7L)

= Drain Locations

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the hoses
may vary slightly depending on installation.
 PCM V-Drive

PLEASURECRAFT
ENGINE GROUP
POWER PLUS
RATIO1.48
MADE IN USA

1/2”
Square

Raw Water
Drain Plug

L510010-09
1

Figure 15-6 Vee Drive CES (5.0/5.7L)

2 From Sea
Water Pickup

= Drain Locations

Note: This diagram is for illustration purposes

only. The actual routing and/or shape of the hoses
may vary slightly depending on installation.

71
WATER FLOW DIAGRAMS - 15
WATER FLOW DIAGRAMS - 15

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

Figure 15-7 Direct Drive Fresh-Water Cooling System (6.0L)

L510010-09
72
 PCM V-Drive

PLEASURECRAFT
ENGINE GROUP
POWER PLUS
RATIO
1.48
MADE IN USA

1/2”
Square

Raw Water
Drain Plug

L510010-09
Figure 15-8 Vee Drive Fresh Water Cooling System (6.0L)
Note: This diagram is for illustration purposes
only. The actual routing and/or shape of the
hoses may vary slightly depending on installation.

= Drain Locations

73
WATER FLOW DIAGRAMS - 15
74
WATER FLOW DIAGRAMS - 15

L510010-09
Figure 15-9 Direct Drive CES (6.0L)
Note: This diagram is for illustration purposes
only. The actual routing and/or shape of the
hoses may vary slightly depending on installation.

= Drain Locations
 PCM V-Drive

PLEASURECRAFT
ENGINE GROUP
POWER PLUS
RATIO1.48
MADE IN USA

1/2”
Square

Raw Water
Drain Plug

L510010-09
Figure 15-10 Vee Drive CES (6.0L)
Note: This diagram is for illustration purposes
only. The actual routing and/or shape of the
hoses may vary slightly depending on installation.

= Drain Locations

75
WATER FLOW DIAGRAMS - 15
HEATER CONNECTIONS - 16
WATER OUT
Remove plug from intake manifold
and install proper barbed fitting.
The plug is located toward the front
of the intake (belt end) on the even
cylinder side.

WATER RETURN
Remove plug from circulation pump
and install proper barbed fitting.
The plug is located on the side of
the circulation pump.

Figure 16-1 5.0/5.7L All Applications

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 HEATER CONNECTIONS - 16
WATER OUT
Remove plug from supplied ball valve fitting and install proper barbed fitting. The fitting is located in the hose above the
heat exchanger on both CES and non-catalyst engines.

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

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

Figure 16-2 6.0L Applications

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77
INSTRUMENTATION WIRING DIAGRAMS - 17
NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.
NOTE A : POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM
THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS.

2-PIN WIRE HARNESS COLOR CHART ENGINE

CIRCUIT CIRCUIT ENGINE HARNESS HARNESS
NUMBER NAME WIRE COLOR
A 1. VBAT RED/PURPLE
2. GROUND BLACK

8-PIN WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS
NUMBER NAME WIRE COLOR
*1. *CHECK GAUGES LAMP GRAY/BLACK*
2. TACHOMETER GRAY
3. COOLANT TEMP TAN
4. BUZZER TAN/BLACK
5. IGNITION PURPLE
6. MIL GREEN/YELLOW
7. STARTER YELLOW/RED
8. OIL PRESSURE DARK BLUE

*CES ENGINES ONLY

TWIN ENGINE
MASTER/SLAVE
CONNECTOR

2-PIN BOAT
HARNESS
CONNECTOR

FUEL TANK
SOLENOID
CONNECTOR

8-PIN BOAT
HARNESS
CONNECTOR

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

Figure 16-1 Typical Instrumentation Wiring

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

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

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 LITERATURE - 18
To obtain service and/or parts literature for your PCM
Marine Engine, contact the following:

PCM Engines
Pleasurecraft Engine Group
Publications Department
1737 Highway 76 East
Little Mountain, SC 29075
1. SERVICE: For more detailed information,
PCM has a detailed service manual available.
This manual contains complete engine and
component disassembly and reassembly
instructions. Troubleshooting and maintenance
charts are also included.

2. PARTS: Parts manuals with exploded views for

service parts are available for all current engine
models.

IMPORTANT: When contacting the factory for service

information, be sure to include your engine model and
serial number to insure the service information you
receive is correct.

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79
FORMS - 19
PCM WARRANTY TRANSFER APPLICATION
The remainder of the original PCM limited warranty is transferable within thirty (30) days of date of sale by the original owner/user to a subsequent
purchaser for the remainder of the unused portion of the original warranty term, provided the engine does not have in excess of 300 hours. The original
date of sale or original in-service date (whichever comes first) begins the warranty coverage period.
Direct Sale by Owner/Dealer Promo/Ski Show User/ or First Operator:
• The second purchaser can be registered as the owner and retain the unused portion of the warranty term by sending the following:
- Original owner’s Warranty Registration Card
- Copy of Bill of Sale/Sales Contract/Operator Contract
- Completed Warranty Transfer Application
- Warranty transfer fee
Transfer Fee:
• The fee for transfer is $100.00. The applicable transfer fee must be submitted via certified check within 30 days of date of sale along with
the transfer application information to: Pleasurecraft Engine Group
P.O. Drawer 369
Little Mountain, S.C., 29075
• A Warranty Registration Card will be issued to the second owner, reflecting the change has been made in the factory computer.
OUTSIDE THE U.S. AND CANADA, CONTACT YOUR LOCAL PLEASURECRAFT DEALER OR WARRANTY SERVICES AT (803) 345-0050 FOR MORE INFORMATION
ON HOW TO APPLY TO THIS PROGRAM.
IMPORTANT! PURCHASER NOTICE: The checks listed below are designed to insure safety and satisfaction. A step-by-step procedure for pre-delivery
can be found in Course 1 of the PCM E-Train Program. Therefore, we require the following inspection be performed at your expense by a qualified
technician prior to delivery. By signature the technician certifies that he/she has checked the installation and operation of the engine and finds it to be
performing properly. All terms in the Limited Warranty located in the Engine Owners Manual still apply.
ENGINE MODEL: ENGINE SERIAL:
TRANS. SERIAL: ENGINE HOURS:
HULL SERIAL #:

Pre-Delivery Checklist
Check for Bulletins Belt and Pulley: Inspect
for Damage
Engine Oil: Check All Drain Plugs: Confirm
Proper Installation
Drive Lube: Check All Fuel Lines:
Confirm No Leaks
Battery Rating, Charge, and Level:
Check Type Information
All Oil Lines:
Confirm No Leaks
Control Adjustments: All Water Lines:
Confirm Proper Operation To PreventConfirm No Leaks
Gauges: Check for Electrical Wiring: Check
Proper Operation
Processing Delay for Proper Installation
Record Propeller Size, Rotation and WOT
WOT RPM_________Diameter_________ Pitch_________Rotation__________

Record Fuel Pressure, Idle ______ Trouble Codes Checked

Record Fuel Pressure, WOT ______ Trouble Codes Cleared

Dealer Reviewed Warranty with Owner

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

(New Owner) (Previous Owner)

NAME: NAME:

ADDRESS: ADDRESS:

CITY,STATE, ZIP CITY,STATE, ZIP

I hereby certify the pre-delivery checklist on engine # and have corrected any abnormality revealed by this inspection.

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

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 FORMS - 19
PCM

SUMMARY OF WARRANTY TERM LIMITS

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

ENGINE MODEL YEAR: WARRANTY COVERAGE TERM:

2005*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission
2006*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission
2007*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission
2008*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission
2009*** 3 years, unlimited hours, GM. 3 years, unlimited hours Transmission
Base Engine 1 year, 200 hours with exclusions.
Note:
*** 2005-2009 Model Year Engines: The remainder of the original PCM limited warranty is transferable to a subse-
quent purchaser, provided the engine does not have in excess of 300 hours and is submitted to PCM within 30
days of the date of sale.

PCM OWNERSHIP CHANGE NOTICE

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

ENGINE MODEL: _________________________

ENGINE SERIAL NUMBER: _________________________

TRANS. MODEL: _________________________

TRANS. SERIAL NUMBER: _________________________

(New Owner) NAME: _____________________________________________________________________________

ADDRESS:______________________________________________________________________________________________________________

CITY,STATE,ZIP: ________________________________________________________________________________

DATE OF PURCHASE: ___________________________________________________________________________

(Previous Owner)NAME: _________________________________________________________________________

ADDRESS: _____________________________________________________________________________________

CITY,STATE,ZIP: ________________________________________________________________________________

L510010-09
81
FORMS - 19
OPERATION AND MAINTENANCE LOG

Engine Port Drive Port Ignition Key Port

Model and
Serial # Stbd. Serial # Stbd. Number Stbd.

Fire Extinguisher Checked Batteries Tested

Gal of Qts of Oil Oil Check Lay Up Launch

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

L510010-09
82
 FORMS - 19
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.

When completed, mail this form to: Pleasurecraft Marine

PO Drawer 369
Little Mountain, SC 29075

Engine Model Engine Serial Number Gear Serial Number

Owner Information

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

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

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

L510010-09
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Intentionally
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L510010-09
84
 NOTES - 20

L510010-09
85
 IMPORTANT
3 Year Transferable Limited Warranty The checks as listed below are designed to insure the safety and
Pleasurecraft Marine Engine Co. (PCM) warrants its new products to be free from defects in material and workmanship under normal use and service
conditions, to the first registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty
satisfaction of you, the owner. By signing this form, the dealer
coverage within 30 days of any subsequent sale/purchases. All components of PCM products are covered under the PCM Warranty, except for those components certifies that he has checked the installation and operation of the
that are warranted by PCM’s suppliers. The obligation of PCM hereunder shall be limited to the repair or replacement with new or remanufactured components, at
its option, of any product or parts thereof which has failed during the period of warranty and which is demonstrated upon examination to have failed due to defective engine and finds it to be performing properly. The owner or his
material and/or workmanship.
PCM’s policy is one of continued improvement of its products and PCM hereby reserves the right to improve and change the design and production of any agent should perform similar inspections periodically to identify
of its products without assuming any obligation to modify products previously manufactured and/or sold.

NO OTHER WARRANTY GIVEN

potential problems before they occur and have any suspected
The obligations set forth in the preceding paragraph are PCM’s sole obligation and owner’s exclusive remedy. PCM makes no other express defects checked and/or corrected immediately.
warranty to the extent that any additional warranty may be implied by law, the term of such implied warranty shall be limited to the warranty term stated herein,
from the date of delivery of the PCM product to the parties outlined herein. Make Owner and Dealer copies of the Registration Card, as
No distributor, dealer, agent or employee of PCM is authorized to grant any other or further warranty or incur any additional warranty obligation on PCM’s
behalf, in connection with the sale of its products. Any qualification or restriction contained herein which is prohibited by any law of mandatory application shall be deemed required. Mail original to Pleasurecraft Engine Group.
to be deleted herefrom, however, such deletion shall have no effect on the remaining provisions hereof, all of which shall remaining full force and effect.

REMEDIES (Please Type Information to Prevent a Processing Delay.)

The obligations of PCM set forth in the first paragraph of this Warranty shall be the exclusive remedy for any breach of Warranty hereunder, and any owner
or user’s sole remedy in the event of breach of the warranties which are made by PCM is repair or replacement of the product or any warranted part thereof as set forth Use Owner’s Copy for Warranty ID until Warranty Identification Card is received by Owner.
herein: with this sole exception, PCM shall not be liable for any direct, or indirect, incidental or consequential damages, including without limitation, any damages
for property damage, loss of use or loss of profits, loss of income, inconvenience, trailering, towing, haul out, launch and/or any other in and out of water expenses, storage Engine Model No. Engine Serial No. Trans. Serial No.
charges, dockage charges, expenses to deliver or pick up the product being warranted to and from the dealer, telephone expenses, lodging expenses, travel expenses,
mechanic travel time and mileage, damage caused by any occurrence of an insurable nature, rental of substitute equipment of any type, removal and replacement and/or
modification of any boat parts to facilitate repairs, moving of furniture, carpets, cleaning, painting, carpenter work, or re-delivery charges.
Owner’s
Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. Name
Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may
not apply to you. Address
Any owner or user hereby waives for himself/herself/itself and his/her/its successor and assigns (a) any and all claims for punitive damages,
and (b) all claims of negligence or strict liability or both, In no event will PCM’s liability exceed the purchase price of the goods which is actually paid City, State Zip
to PCM.
Date of Sale Dealer
WARRANTY COVERAGE, TERM Signature
This Warranty is extended only to the first registered owner or registered user, and all subsequent user who, in accordance with PCM’s warranty transfer
policy, transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases, for the period specified below: Selling Premier
All components, other than and those itemized below, are warranted for a period of three (3) years from the date of delivery to the first registered owner or Dealer Dealer #
registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty coverage within 30 days
of any subsequent sale/purchases in non-commercial use. In case of commercial use, the term of this Warranty shall be the shorter of (a) a period of six (6) months from
the date of delivery to the first registered owner or registered user or (b) the expiration of 200 hours of use. Address
Items not covered under this warranty;
(A) Water pump impellers are not covered by this Warranty. Predelivery Checklist
(B) Seals, gaskets, O-rings, and other material affected by time are not covered by this Warranty if their effectiveness is reduced by
an extended storage period prior to sale or use. Check for Bulletins Belt and Pulley: Inspect
OBTAINING PERFORMANCE UNDER WARRANTY for Damage
PCM’s warranty registration form should be prepared by your selling dealer, executed by you and the dealer and mailed, by you, to PCM within 30 days
after the date of purchase. Upon receipt of the warranty registration form, PCM will issue to you a personalized owner’s registration card which will be mailed directly to Engine Oil: Check All Drain Plugs: Confirm
you. If the owner’s registration card is not received within eight (8) weeks after the date of purchase, please write PCM at the address below.
At the time that a claim for warranty service is made, the owner’s registration card should be presented to the person or entity providing warranty service.
Proper Installation
Authorized PCM dealers or distributors are entitled to be reimbursed by PCM for some or all of the expense of warranty repairs, thus, service under the terms of this Drive Lube: Check
Warranty will be performed by an authorized PCM dealer or distributor without charge for established flat rate labor or replacement parts, other than items not covered by All Fuel Lines:
the Warranty, such as , but not limited to, lubricants, spark plugs, points, and other items which are normally frequently replaced as part of routine maintenance. Charges
for additional non-warranty work and/or additional dealer charges for labor relative to warranty work in excess of flat rate must be paid for by the owner.
Confirm No Leaks
Prior authorization in writing must be obtained from PCM for any warranty repairs over $50.00 and in all cases where the owner fails to establish the
Battery Rating, Charge, and Level:
purchase and warranty expiration dates with the owner’s registration card sent upon receipt of the warranty registration form by PCM. While failure to present the Check All Oil Lines:
owner’s registration card will not prevent you from obtaining coverage hereunder, this Warranty shall not be effective and, therefore, cannot be honored until the product Confirm No Leaks
purchase date can be confirmed by PCM. If the card is lost, communicate with PCM at the address listed below, and, for a processing fee of $10.00, a new owner’s
registration card will be issued to you. Control Adjustments: All Water Lines:
Any questions concerning service, parts or this Warranty should be directed to your selling dealer. If your dealer is unable to assist or if you relocate or are
travelling or need a referral to your nearest dealer contact: Pleasurecraft, P.O. Drawer 369, Little Mountain, SC 29075 Confirm Proper Operation Confirm No Leaks
FAILURES EXCLUDED FROM WARRANTY
This Warranty will not apply to any failure which results from accidents, sinking, fire, neglect, abuse, or abnormal service or use, such as racing, towing
Gauges: Check for Electrical Wiring: Check
or operation in water of insufficient depth, or to any failure resulting from improper installation, improper adjustments, repairs or improper delivery service, or to any failure Proper Operation
resulting from the use of parts, fuels, oils or lubricants not suitable for use with the product and/or materials or parts not approved by PCM. This Warranty does not apply
for Proper Installation
to any engine or drive which has been modified, or altered, or repaired in such a manner as, in the opinion of PCM, to affect its stability, reliability or performance. Further,
this Warranty will not apply to failure resulting from use of non-recommended lubricants or fuels, failure to follow maintenance or lubrication schedules, failure caused or Record Propeller Size, Rotation and WOT
contributed to by contaminated fuel, failure caused by improper installation or misapplication of the engine or drive, failure resulting from the owner’s or operator’s failure to
exercise due or normal care and precaution, or failure of components and/or assemblies that are warranted by PCM suppliers. WOT RPM_________Diameter_________ Pitch_________Rotation__________
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, all requested information recorded and that the selling dealer has Record Fuel Pressure, Idle ______ Trouble Codes Checked
signed the warranty registration. Record Fuel Pressure, WOT ______
2 Owner or user shall promptly mail the warranty registration to PCM after accepting delivery. Trouble Codes Cleared
3 Owner or user shall follow the instruction in the owner’s manual regarding operation, break-in, lubrication, and fuel.
4 Owner or user shall follow or comply with the maintenance schedule, operation limits, and lay up instruction, as outlined in the owner’s manual.
Dealer Reviewed Warranty with Owner
CHOICE OF LAW
This Limited Warranty shall be governed by, and construed and interpreted in accordance with, the laws of the State of Ohio, except only to the extent
replaced or precluded by other law of mandatory application. Owner’s
Signature Date
SPECIAL STATE LEGAL REQUIREMENTS
Boat Hull
This Warranty gives you specific legal rights, and you may also have other rights which vary from State to State.
The PCM California Emissions Warranty and California Emissions Control Warranty Statement is a separate document included in this Manual. Any Make Serial # Length
questions concerning the Emissions Warranty can be obtained by calling 1-803-345-0050.

L585002
Pleasurecraft Engine Group PO Drawer 369 Little Mountain, SC 29075
From: FIRST
CLASS
POSTAGE
MAIL TO:
WARRANTY DEPARTMENT
PLEASURECRAFT ENGINE GROUP
P.O. DRAWER 369
LITTLE MOUNTAIN, SC 29075
 This Page
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Pleasurecraft Engine Group 1737 Highway 76 East, Little Mountain SC 29075