PleasureCraft Engine Group crusader Owner's Operation And Maintenance Manual
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PleasureCraft Engine Group crusader Owner's Operation And Maintenance Manual

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OWNER'S OPERATION
and
MAINTENANCE MANUAL
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  • Page 1 OWNER’S OPERATION MAINTENANCE MANUAL A Division of...
  • Page 2 The descriptions and specifi cations contained in this manual were in effect at the time of printing. Crusader Marine Engines’ policy of continued improvement reserves the right to change specifi cations or design without notice and without obligation.

  • Page 3: Table Of Contents

    Items Not Covered Under the Limited Warranty ................Things You Should Know About The Warranty ................California Emission Control Warranty Statement ........Crusader, Inc. Model Years 2003-2008 General Emissions Warranty Coverage ........................ Marine Transmissions ....................Captain’s Choice Series Engines ......................
  • Page 4 TABLE OF CONTENTS .................... High Transmission Fluid Temperature ....................OPERATING INSTRUCTIONS 28-32 ........................ Engine Alarm System ........................Instrumentation ........................Remote Controls ..................Starting Engine (Fuel Injected Engines) ......................... Shifting Transmission ........................Stopping Engine ....................Freezing Temperature Operation ....................Operation in High Debris Areas .................
  • Page 5 TROUBLESHOOTING 77-79 ....................WATER FLOW DIAGRAMS 80-83 ..................INSTRUMENTATION WIRING DIAGRAM .......................... LITERATURE ..........................FORMS 87-91 ................CRUSADER OWNERSHIP CHANGE NOTICE ......CRUSADER WARRANTY TRANSFER APPLICATION (PORT OR SINGLE ENGINE) ........CRUSADER WARRANTY TRANSFER APPLICATION (STARBOARD ENGINE) ........................... NOTES L510001-05...

  • Page 6: Service And Warranty

    “common sense” explosion hazard and should be avoided. operation, are major accident prevention measures. Always request that genuine Crusader Marine 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;...

  • Page 7: Crusader Marine Engines' Commitment To You

    CRUSADER MARINE ENGINES’ COMMITMENT TO YOU Crusader Marine Engines is committed to assuring your satisfaction with your new Crusader engine. Your Dealer also wants you to be completely satisfi ed, and invites you to return for all your servicing needs, both during and after the warranty period.

  • Page 8: Engine Operation And Care

    SERVICE AWAY FROM HOME If you are away from home and your local dealer, and the need for service arises, contact the Crusader Captain’s Club™ Concierge using your exclusive Captain’s Club toll-free number. The Club Concierge is there to support your local dealer or locate the closest Crusader authorized technician.

  • Page 9: Replacement Parts Inquiries

    Only authorized distributors can purchase parts from the factory. Crusader Marine Engines does not sell to unauthorized dealers or retail customers. When checking on parts, the dealer will require the engine model and serial number to order the correct parts.

  • Page 10: Crusader Marine Engines One-Year Limited Warranty (For Engines Sold And Used In The United States And Canada)

    Crusader will arrange for the correction of all defects under this Limited Warranty to be made free of charge at the selling dealership or an authorized Crusader service center. Crusader, in its discretion, may provide for the repair or replacement of any defective part at Crusader’s facility.
  • Page 11 Any owner/user hereby waives for himself/herself/itself and his/her/its successors 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 Crusader’s liability exceed the purchase price of the Products which is actually paid to Crusader.

  • Page 12: Items Not Covered Under The Limited Warranty

    • Repairs made necessary by normal wear, rust, electrolysis or corrosion, or by the use of the parts or accessories which are either incompatible with the Crusader product or adversely affect its operation, performance or durability. •...

  • Page 13: Things You Should Know About The Warranty

    Production Changes Crusader Marine Engines and its Distributors reserve the right to make changes in the engines built and/or sold by it at any time without incurring any obligation to make the same or similar changes on engines previously built and/or sold.

  • Page 14: California Emission Control Warranty Statement

    Crusader recommends that you retain all receipts covering maintenance on your inboard engine, but Crusader cannot deny warranty coverage solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

  • Page 15: Crusader, Inc. Model Years 2003-2008 General Emissions Warranty Coverage

    Crusader Owners/Operators Manual, is warranted for the period of two (2) years. If the part fails during the period of warranty coverage, Crusader will repair or replace the defective part at any Crusader warranty station. The repair or replacement will be performed at no charge to the owner.
  • Page 16 11. Crusader original equipment parts are “identical in all material respects to that part as described in the engine manufacturer’s application for certifi cation”. The use of any replacement parts not supplied by Crusader may not meet this requirement and will be grounds for disallowing a claim made under this Warranty.

  • Page 17: Marine Transmissions

    Crusader Marine Engines are equipped with transmissions designed, built and warranted by other manufacturers. Although much of the transmission warranty is handled through Crusader Marine Engines, there may be issues for which, you, the owner, may want to contact the transmission manufacturer directly. The transmission suppliers are listed below for your reference.

  • Page 18: Resolving A Service Problem

    RESOLVING A SERVICE PROBLEM Your satisfaction and faith in the product are of major importance to your dealer and to Crusader Marine Engines. Any problems with service, warranty or operation of your Crusader powered boat will be resolved by your dealer. He should be your primary source of information on your boat.

  • Page 19: Dealers Responsibilities

    In general, the dealer’s responsibilities to you, the customer, include pre-delivery inspection and preparation such as: • Make sure that the boat is properly equipped • Prior to delivery, make certain that the Crusader Engine is in proper operating condition • Make all necessary adjustments for maximum effi ciency •...

  • Page 20: Transferable Warranty

    The second owner can be registered as the new owner, and may retain the unused portion of the limited warranty. The forms and instructions necessary to transfer the unused portion of the Crusader One year Limited Warranty are provided in Forms, section 18 of this manual.

  • Page 21: Notes

    SERVICE and WARRANTY - 1 L510001-05...

  • Page 22: Boating Responsibility

    BOATING RESPONSIBILITIES - 2 CARBON MONOXIDE HAZARD To fi nd 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.

  • Page 23: Safe Boating Suggestions

    Crusader engine. When service and maintenance • Know your boat’s loading and operating are required, return to your authorized Crusader Marine limitations. DO NOT OVERLOAD! Engines Dealer. • Make periodic checks of safety equipment onboard.

  • Page 24: Rules Of The Road

    BOATING RESPONSIBILITIES - 2 RULES OF THE ROAD Boat Capacity • Load only to manufacturer’s specifi cations Channel Buoy Guide • Distribute load evenly; keep it low • Passengers should only ride on the parts of the The color of the paint is the only characteristic which boat that are designed for that purpose has the same meaning on all buoys.

  • Page 25: Engine Identification

    ENGINE IDENTIFICATION - 3 ENGINE IDENTIFICATION ENGINE SPARK W.O.T. Fuel Oct Reg..........MIN 87 AVG MODEL PLUG Eng Oil Type....Above 50 F - SAE 15W-40 "SJ" Below 50 F - SAE 5W-40 "SJ" When ordering service parts or obtaining information, Trans Fluid Type...........Dexron III 5.7 MPI AC - MR43LTS 4800-5000...

  • Page 26: 2005 Model Identifi Cation / Advisory

    MODEL C X L X H F L 245 M SERIAL 651254 Space: MANUFACTURER Spaces: DRIVE GEAR RATIO OR REDUCTION C - Crusader The drive gear ratio will appear in these spaces Space: FACTORY FRESHWATER / CLOSED COOLING which identifi es the production gear specs. The X-Freshwater Cooled example gear number shown is a (2.45:1).

  • Page 27: Electronic Fuel Injection Information

    Also, the light may go The Crusader Marine Engines covered in this manual out or become intermittent, but a trouble code will be are equipped with an Electronic Fuel Injection (EFI) logged for future diagnosis.

  • Page 28: Power Reduction Mode

    ELECTRONIC FUEL INJECTION INFORMATION - 4 POWER REDUCTION MODE High Engine Coolant Temperature The ECM monitors engine oil pressure, engine coolant During operation, if the engine coolant temperature temperature and transmission oil temperature whenever exceeds 220° F (104.8° C), the engine enters “Power the engine is running.

  • Page 29: Low Engine Oil Pressure

    WATER TRANS TEMP TEMP TEMP TEMP Figure 4-3 OIL PRESS Light Illuminated Figure 4-4 TRANS TEMP Light Illuminated If a problem occurs in any of the aforementioned areas, return the boat to your Crusader Marine Engines Dealer for service. L510001-05...

  • Page 30: Operating Instructions

    OPERATING INSTRUCTIONS - 5 ENGINE ALARM SYSTEM (OPTIONAL) INSTRUMENTATION The Crusader engine electronic system is programmed Boat manufacturers install many different types of to control the engine alarm system. This system utilizes instrumentation on boats. Become familiar with the an audible alarm and/or optional indicator lamps to warn...

  • Page 31: Remote Controls

    OPERATING INSTRUCTIONS - 5 20 30 20 30 PORT STBD SLOW SLOW SYNC TACH TACH TEMP TEMP HOURS CHECK CHECK ENGINE ENGINE VOLT FUEL VOLT BILGE BLOWER SWITCH IGNITION FUSES IGNITION SWITCHES Figure 5-1 Typical Instrument Panel REMOTE CONTROLS SHIFT THROTTLE CONTROL Your boat may be equipped with one of many different...

  • Page 32: Starting Engine (Fuel Injected Engines)

    OPERATING INSTRUCTIONS - 5 STARTING ENGINE (FUEL INJECTED ENGINES) WARNING Electrical, ignition and fuel system components on Crusader Marine Engines are designed and Check for Check for signs of manufactured to comply with U.S. Coast Guard rules signs of external leaks and regulations to minimize risks of fi...

  • Page 33: Shifting Transmission

    Neutral. Figure 5-3 Throttle Position Setting NEUTRAL NOTICE: If engine still fails to start, contact your Crusader Marine Engines Dealer for service. REVERSE GEAR 8. Check engine oil pressure immediately after the engine starts. If oil pressure is not within specifi...

  • Page 34: Stopping Engine

    OPERATING INSTRUCTIONS - 5 STOPPING ENGINE FREEZING TEMPERATURE OPERATION When returning to the dock, or whenever stopping the If the possibility of freezing exists, the cooling system engine, bring the throttle back to the idle position. After must be protected after the engine is shut off to prevent the engine reaches idle speed, turn the ignition key to freeze damage to the engine.

  • Page 35: Conditions Affecting Operation

    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.

  • Page 36: Propeller Selection

    See NORMAL CRUISING SPEEDS in SPECIFICATIONS. Problems caused by WOT operation are considered abuse and are not covered under the Crusader Warranty. NOTICE: These engines incorporate an RPM “REV LIMIT” in order to prevent the engine from over-revving. L510001-05...

  • Page 37: Engine Break-In Period

    NOT EXCEED MAXIMUM RPM. (RPM should dealer and have the recommended 25-hour inspection cease climbing after 10 to 20 seconds). done. NOTICE: Crusader Marine Engines assumes no CAUTION responsibility for the costs related to the 25-hour inspection. This is the owner’s responsibility.

  • Page 38: 25-Hour Engine Inspection

    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 Crusader servicing dealer should be contacted clamps for adequate tightness. to perform the necessary checks and adjustments to ensure the proper engine performance.

  • Page 39: Fuel Requirements

    Such damage is not covered by the Crusader Marine Engines warranty. • Hard starting and operating diffi culties (vapor...

  • Page 40: Oil Requirements

    Crankcase oil and oil fi lter change - Recommended added to the engine oil by the customer are unnecessary intervals: and may be harmful. Crusader Marine Engines does not review, approve or recommend such products. • Initial oil change - 1st 60 days or 25 hours of operation, whichever occurs fi...

  • Page 41: Engine Maintenance

    Some procedures may be performed by the owner/operator while others should be performed by an authorized Crusader Marine Engines Dealer. Before performing any maintenance or repair procedure not covered in this manual, it is strongly recommended that a Crusader Marine Engines repair manual be purchased and read thoroughly.
  • Page 42 CAUTION Do not attempt to remove the transmission dipstick while the engine is running. Hot transmission fl uid Crusader Marine Engines uses marine transmissions could be sprayed from the dipstick hole. supplied by several manufacturers. The maintenance requirements can be different between 2.

  • Page 43: Lubrication

    ENGINE MAINTENANCE - 11 LUBRICATION Shift Cable Lubricate pivot points and exposed cable (Figure 11-5) Throttle Cable with SAE 30W-30 engine oil. Lubricate pivot points and exposed cable (Figure 11-3) with SAE 30W-30 engine oil. BALL JOINT LUBRICATION CABLE CLIP POINTS LUBRICATION POINTS...

  • Page 44: Electrical System Circuit Breaker(S)

    If the engine will not crank when the ignition key is turned to the START position, fi rst check that the shift lever is in Crusader engines utilize fuses to control the fuel pump, neutral position. If the main circuit breaker is not tripped, ECM and fuel injectors.

  • Page 45: Battery

    ENGINE MAINTENANCE - 11 Follow maintenance instructions and warnings as BATTERY supplied by the battery manufacturer. If this information is not available, follow these guidelines for the proper WARNING battery care. Battery electrolyte is a corrosive acid and should • Do not operate the engine with an open in the be handled with care.

  • Page 46: Fresh Water Cooling System Sacrifi Cial Zinc Anode

    Remove and check condition of zinc pencil every 30 days. Replace if more than 50% a zinc anode which is marked by a decal. To check, missing with Crusader Part #10972. P/N 23627 remove the plug and visually check the condition of the zinc rod.

  • Page 47: Checking Coolant Level

    ENGINE MAINTENANCE - 11 CHECKING COOLANT LEVEL DEGAS BOTTLE WARNING Do not remove cooling system fi ller cap when the engine is hot. Allow the engine to cool and then remove the pressure cap slowly, allowing the pressure to vent. Hot coolant, under pressure, may discharge violently and cause severe burns.

  • Page 48: Flushing Cooling System - Sea-Water Section

    ENGINE MAINTENANCE - 11 FLUSHING COOLING SYSTEM - SEA-WATER SECTION To prevent silt and/or salt build-up in the cooling system (fresh or raw-water cooled), fl ush the sea-water section of the cooling system with fresh water at specifi ed intervals. ATTACH FLUSHING CAUTION...

  • Page 49: Testing Coolant For Alkalinity

    ENGINE MAINTENANCE - 11 TESTING COOLANT FOR ALKALINITY DRAINING FRESH-WATER COOLING SYSTEM It is recommended that the coolant in the fresh-water NOTICE: To protect the environment, dispose of section be tested each year for alkalinity. Coolant coolant properly. Check your local restrictions for proper that is not alkaline has lost the effectiveness of its disposal instructions of removed coolant.

  • Page 50: Filling Fresh-Water Cooling System

    ENGINE MAINTENANCE - 11 4. Start the engine and operate at idle speed (800- FILLING FRESH-WATER COOLING SYSTEM 1000 RPM) to purge any air from the system. A new extended life engine coolant known as DEX- 5. Add additional coolant into the Degas Bottle to COOL™...

  • Page 51: Cleaning Sea-Water Section Of Heat Exchanger (Fresh-Water Cooled Applications Only)

    ENGINE MAINTENANCE - 11 CLEANING SEA-WATER SECTION OF HEAT EXCHANGER - FRESH-WATER COOLED HEAT EXCHANGER MODELS ONLY The sea-water section of the heat exchanger should THERMOSTAT be cleaned whenever there is a noticeable decrease in HOUSING cooling effi ciency. You may use the following procedure for cleaning, or, if the build-up of scale and mineral deposits is heavy, it is recommended that the heat exchanger be removed and taken to a repair facility to be...

  • Page 52: Fuel System Description

    fi ltration and water separation. components, as residual pressure may be present. The FCC system incorporates two (2) fuel pumps to provide an uninterrupted fl ow of fuel to your Crusader marine engine. Fuel is fed into the FCC bowl by a low- WARNING pressure, high-volume electric fuel pump.

  • Page 53: Servicing The Fcc

    ENGINE MAINTENANCE - 11 FUEL SUPPLY LINE FUEL RETURN LINE 5.0/5.7L ONLY FUEL TANK FROM FUEL TANK FUEL CONTROL CELL PRIMARY LOW-PRESSURE FUEL FUEL PUMP FILTER Figure 11-13 Fuel Control Cell (FCC) Fuel System (Typical) Servicing the FCC The frequency of draining the water or replacing the fi lter element is determined by the contamination level of the fuel.

  • Page 54: Fcc Service Instructions (Screw-On Canister)

    ENGINE MAINTENANCE - 11 FCC Service Instructions (FCC Screw-on Canister) WARNING FUEL PRESSURE Extreme caution must be exercised when servicing REGULATOR the fuel system. The fuel system operates under high pressure. Use caution when removing or replacing components, as residual pressure may be present. FUEL FUEL PUMP...

  • Page 55: Fcc Service Instructions (Clamp-On Canister)

    ENGINE MAINTENANCE - 11 FCC Service Instructions (FCC Clamp-on Canister) WARNING 6.0L 5.0/5.7L Extreme caution must be exercised when servicing the fuel system. The fuel system operates under O-RINGS high pressure. Use caution when removing or FUEL PRESSURE REGULATOR replacing components, as residual pressure may be present.

  • Page 56: Primary Fuel Filter

    ENGINE MAINTENANCE - 11 FUEL SUPPLY LINE FUEL RETURN LINE ELECTRIC FUEL PUMP FUEL SUPPLY INLET FUEL COOLER PRIMARY WATER LOW-PRESSURE CANISTER FUEL SEPARATING FUEL PUMP FILTER FUEL FILTER Figure 11-16 Returnless-Type Fuel System (Typical) Primary Fuel Filter 1. Close the fuel supply line (shut-off valve). Start the engine and let it run until it stalls from lack of Primary Fuel Filter Service KIT#: RP077014 fuel.

  • Page 57: Water Separating Fuel Filter

    ENGINE MAINTENANCE - 11 8. Prime the fuel system. Refer to procedures in FLAME ARRESTOR this section. At specifi ed intervals, the fl ame arrestor should be 9. Turn the key to START position and crank the checked for blockage caused by dirt or other foreign engine until it starts, or 30 seconds elapse.

  • Page 58: Accessory Drive Belt

    Figure 11-20 Belt Tensioner (8.1L) 8.1L ACCESSORY DRIVE BELT DRIVE BELT REPLACEMENT (8.1L) The Crusader 8.1L engine uses a single serpentine belt 8.1L SERPENTINE BELT #: R066024A to drive the engine water circulation pump, sea-water 1. Note the routing of the belt before removing.
  • Page 59 ENGINE MAINTENANCE - 11 6.0L ACCESSORY DRIVE BELT The Crusader 6.0L engine uses a single serpentine belt to drive the engine water circulation pump, sea-water pump and the alternator. DRIVE BELT REPLACEMENT (6.0L) 6.0L SERPENTINE BELT #: R066027 1. Note the routing of the belt before removing.
  • Page 60 ENGINE MAINTENANCE - 11 5.0/5.7L ACCESSORY DRIVE BELT The Crusader 5.0/5.7L engines use a single serpentine belt to drive the engine water circulation pump, sea- water pump and the alternator. Belt Tensioner Circulation Raw Water Pump Pump Figure 11-24 Belt Tensioner (5.0/5.7L) Alternator DRIVE BELT REPLACEMENT (5.0/5.7L)

  • Page 61: Changing Oils

    ENGINE MAINTENANCE - 11 CHANGING OILS OIL PUMP WARNING IMPORTANT: The Federal Water Pollution Control Act prohibits the discharge of oil or oily waste into or upon the navigable waters and continuous zone of the United States, if such discharge causes a fi...

  • Page 62: Engine Alignment

    ENGINE MAINTENANCE - 11 ENGINE ALIGNMENT CAUTION Engine must be properly aligned, or vibration, noise and damage to the transmission output shaft oil seal and bearings may result. IMPORTANT: Engine alignment MUST BE RECHECKED with the boat in the water, fuel tanks full and with a normal load on the boat.
  • Page 63 ENGINE MAINTENANCE - 11 Figure 11-29 Centering Propeller Shaft - 8 Degree Down Figure 11-31 Angular Alignment - “V” Drives Angle 4. Check for any angular misalignment. Hold coupling faces tightly together and check for a gap between the coupling faces, with a 0.003 in. (0.07 mm) feeler gauge, at 90-degree intervals.
  • Page 64 ENGINE MAINTENANCE - 11 1.0 in. MAX (25 mm) BOLTS LOWER ENGINE RAISE ENGINE Figure 11-32 Engine Mount Adjustment 5. If the coupling center lines are not aligned, or if TRUNNION BOLT the coupling faces are more than 0.003 in. (0.07 mm) out of parallel, adjust the engine mounts as follows: Figure 11-33 Engine Extension...

  • Page 65: Engine Maintenance Log

    ENGINE MAINTENANCE - 11 ENGINE MAINTENANCE LOG Operating Date Maintenance/Repair Hours L510001-05...

  • Page 66: Maintenance Schedule

    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 Check oil level - Engine crankcase Check oil level - Transmission Engine Assembly (complete - Check for obvious leaks (water, oil, fuel and exhaust)
  • Page 67 (C) All Velvet “V” Drive transmissions - Use Dexron III automatic transmission fl uid All Walters “V” Drive transmissions - Use Exxon Spartan EP-68 or SAE 30 engine oil All Crusader “V” Drive transmissions - Use SAE 80W-90 gear oil (D) Use WD-40 penetration oil or equivalent L510001-05...

  • Page 68: Visual Inspection

    Touch up scratches, nicks and corrosion damage to VISUAL INSPECTION the exterior fi nish of the engine. Spray paint may be obtained from your local Crusader Marine Engines It is important for the owner/operator to visually inspect dealer. the complete engine assembly at regular intervals. Most often, costly repairs can be avoided if potential problems Protect engine fi...

  • Page 69: Filter Requirements

    ENGINE MAINTENANCE - 11 FILTER REQUIREMENTS Description Part No. Oil Filter (remote-mounted) 22679 Primary Fuel Filter Element RP077014 Water Separator Fuel Filter Element 47047 Fuel Control Cell (FCC) Fuel Filter Element RP080026 ON-BOARD PARTS KITS Description Part No. ON-BOARD PARTS KIT 5.7L (LH) 2005 TO PRESENT, FCC FUEL SYSTEM RK173089D-05 Box, On-Board (1)
  • Page 70 ENGINE MAINTENANCE - 11 ON-BOARD PARTS KITS Description Part No. ON-BOARD PARTS KIT 5.7L, RETURNLESS FUEL SYSTEM (‘05 TO Present - LH) RK173089F-05 Box, On-Board (1) 22433 Belt, Serpentine (1) R066028 Rotor, Distributor (HVS) (1) R103011 Cap, Distributor (HVS) (1) RA108009 Fuse, 20 Amp (3) R153017B...
  • Page 71 ENGINE MAINTENANCE - 11 ON-BOARD PARTS KITS Description Part No. ON-BOARD PARTS KIT 6.0L MPI RETURNLESS FUEL SYSTEM - ‘05 To Present RK173092A-05 Box, On-Board (1) 22433 Belt, Serpentine (1) R066027 Fuse, 20 Amp (3) R153017B Relay, 12V, Fuel Pump, Ignition, Start (1) R130011A SparkPlug, Set, (Platinum) (1) RP030011...

  • Page 72: Engine Specifications

    ENGINE SPECIFICATIONS - 12 L510001-05...
  • Page 73 ENGINE SPECIFICATIONS - 12 L510001-05...

  • Page 74: Engine Specifications

    ENGINE SPECIFICATIONS - 12 5.0 / 5.7 Liter 5.7 Liter 6.0 / 8.1 Liter LH ROTATION LH ROTATION RH ROTATION FRONT FRONT FRONT DISTRIBUTOR Rotation Rotation FLYWHEEL END OF ENGINE ALL V-8 MODELS FIRING ORDER: FIRING ORDER: FIRING ORDER: 1-8-4-3-6-5-7-2 1-2-7-5-6-3-4-8 1-8-7-2-6-5-4-3 Figure 12-1 V-8 Firing Orders...

  • Page 75: Out-Of-Season Storage

    (Spray IMPORTANT: This service should be performed by 5 seconds per cylinder, minimum.) Turn the an Authorized Crusader Dealer. crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders. CAUTION...

  • Page 76: Draining Instructions

    OUT-OF-SEASON STORAGE - 13 DRAINING INSTRUCTIONS 4. Remove the raw water pump impeller. (See ENGINE MAINTENANCE) If inspection proves the impeller to be in good condition, store it in CAUTION an accessible spot for re-installation at the end of the storage period. A damaged or badly worn If the boat is to remain in the water during or after impeller should be discarded and a new one draining, close the seacock to prevent a siphoning...

  • Page 77: Out-Of-Season Engine Warm-Up

    If it is necessary to start your engine(s) during cold IMPORTANT: This service should be performed by weather storage, refer to the following procedure. an Authorized Crusader Marine Engines Dealer. 1. Refer to “Recommissioning After Storage” to When recommissioning the engine after storage, the...

  • Page 78: Out-Of-Season Storage

    OUT-OF-SEASON STORAGE - 13 RECOMMISSIONING AFTER STORAGE CAUTION Failure to remove the excess storage oil from the engine’s cylinders can cause hydrostatic locking to occur, and severe damage to the engine. 8. Before starting the engine, be sure there is not an excess amount of storage oil left in the cylinders.

  • Page 79: Troubleshooting

    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 Crusader Marine Engines Servicing Dealer for assistance. Malfunction Possible Cause Corrective Action “Check Engine”...
  • Page 80 TROUBLESHOOTING - 14 Malfunction Possible Cause Corrective Action Engine Overheats Loose or worn drive belt(s) Adjust or replace the belts as necessary. Collapsed, kinked or leaking Replace the hoses. hoses. Transmission/engine oil cooler Remove the water hoses and fl ush plugged in opposite direction of the normal fl...
  • Page 81 Contaminated fl uid Determine and correct the contamination source and change the fl uid. Engine misses, runs rough Ignition system malfunction Contact Crusader Marine Engines and/or backfi res Dealer. Plugged fuel fi lters Replace the fuel fi lters. Faulty fuel pump.

  • Page 82: Water Flow Diagrams

    WATER FLOW DIAGRAMS - 15 Figure 15-1 Fresh-Water Cooling System 5.0/5.7L (Typical) L510001-05...
  • Page 83 WATER FLOW DIAGRAMS - 15 = RAW WATER FLOW = FRESH WATER FLOW = 5 Drain Locations Remove Hoses from raw water pump and drain hoses completely Returnless Fuel System IMPORTANT: Accessory (i.e. heater, hot water tank) Hook Up NOTE: Location is the location in order to hook up a hot water accessory.
  • Page 84 WATER FLOW DIAGRAMS - 15 Figure 15-3 Fresh-Water Cooling System 8.1L (Typical) L510001-05...

  • Page 85: Water Flow Diagrams

    WATER FLOW DIAGRAMS - 15 NORMAL OPERATION WARM-UP OPERATION BYPASS BYPASS HEAT HEAT EXCHANGER EXCHANGER FROM FROM EXHAUST EXHAUST MANIFOLDS MANIFOLDS COOLANT FLOW OVER TEMPERATURE OPERATION CLOSED BYPASS HEAT EXCHANGER FROM EXHAUST MANIFOLDS Figure 15-4 Thermostat Housing Waterfl ow Diagrams and Fill-Riser Waterfl ow - 8.1L Fresh-Water Cooled L510001-05...

  • Page 86: Instrumentation Wiring Diagram

    INSTRUMENTATION WIRING DIAGRAMS - 16 ENGINE WIRE HARNESS COLOR CHART HARNESS CIRCUIT CIRCUIT ENGINE HARNESS NUMBER NAME WIRE COLOR GROUND BLACK TACHOMETER GRAY WATER TEMPERATURE ENGINE ALARM TAN/BLACK IGNITION PURPLE/WHITE BATTERY RED/WHITE STARTER YELLOW/RED OIL PRESSURE LT. BLUE CHECK ENGINE LIGHT BROWN/WHITE DATA LINE ORANGE/BLACK...

  • Page 87: Literature

    LITERATURE - 17 To obtain service and/or parts literature for your Crusader Marine Engine, contact the following: Crusader Marine Engines Pleasurecraft Engine Group Publications Department 1737 Highway 76 East Little Mountain, SC 29075 IMPORTANT: When contacting the factory for service...

  • Page 89: Forms

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

  • Page 91: Crusader Warranty Transfer Application (Port Or Single Engine)

    (PORT OR SINGLE ENGINE) The remainder of the original Crusader 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(s) operating hours do not exceed 300. The original date of sale or original in-service date (whichever comes fi...

  • Page 93: Crusader Warranty Transfer Application (Starboard Engine)

    (STARBOARD ENGINE) The remainder of the original Crusader 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(s) operating hours do not exceed 300. The original date of sale or original in-service date (whichever comes fi...

  • Page 95: Notes

    NOTES - 19 L510001-05...
  • Page 96 Pleasurecraft Engine Group 1737 Highway 76 East, Little Mountain SC 29075...

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