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PCM HO303 MPI Owner's Operation And Maintenance Manual

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OWNER'S OPERATION
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MAINTENANCE MANUAL
A Division of

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Summary of Contents for PCM HO303 MPI

  • Page 1 OWNER’S OPERATION MAINTENANCE MANUAL A Division of...
  • Page 2 This Page Was Intentionally Left Blank...
  • Page 3 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.
  • Page 4 PROPOSITION 65 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Part Number - L510010-11 Printed 04/11...

  • Page 5: Table Of Contents

    Registration Information (Warranty Registration Card is located at the back of this manual) ..................... 3-Year Transferable Limited Warranty ................. Federal/California Emission Control Warranty Statement ............PCM Inboard Marine Engine General Emissions Warranty Coverage ..........................Safety Information ..........................Replacement Parts ...........................
  • Page 6 TABLE OF CONTENTS ....................Electrical System Relay and Fuse Block ......................Electrical System Fuses ........................Boat’s Ignition Fuse ..................Electrical System Wiring and Connectors ............................ Battery ................. Fresh Water Cooling System Sacrifi cial Zinc Anode ......................Checking Coolant Level ................Flushing Cooling System - Sea-Water Section ......................

  • Page 7: Introduction

    REGISTRATION INFORMATION (Warranty Registration Card is located at the back of this manual) Shortly after your purchase is registered with PCM, you will be mailed your Warranty Card and a Customer Survey. We appreciate your feedback and encourage you to fi ll out the survey after you have had a chance to run your boat for several weeks.

  • Page 8: 3-Year Transferable Limited Warranty

    Warranty shall not be effective and, therefore, cannot be honored until the product purchase date can be confi rmed by PCM. If the card is lost, communicate with PCM at the address listed below, and, for a processing fee of $10.00, a new owner’s registration card will be issued to you.

  • Page 9: Federal/California Emission Control Warranty Statement

    INTRODUCTION - 1 FEDERAL/CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The Environmental Protection Agency (EPA), California Air Resources Board (CARB) and Pleasurecraft Marine Engine Co. (hereinafter “Pleasurecraft”) are pleased to explain the emission control system warranty on your inboard marine engine manufactured after January 1, 2008 for CARB and after January 1, 2011 for EPA.

  • Page 10: Pcm Inboard Marine Engine General Emissions Warranty Coverage

    INTRODUCTION - 1 PLEASURECRAFT MARINE ENGINE CO. GENERAL EMISSIONS WARRANTY COVERAGE (Engines Manufactured after January 1, 2008 for CARB and after January 1, 2011 for EPA) 1. Pleasurecraft Marine Engine Co. (hereinafter referred to as “Pleasurecraft”) warrants to the fi rst owner purchasing at retail, and all subsequent owners, of every Pleasurecraft inboard marine engine manufactured after January 1, 2008 for CARB and after January 1, 2011 for EPA, that the emissions control devices on Pleasurecraft inboard marine engines are free from defects in materials and workmanship when...
  • Page 11 INTRODUCTION - 1 8. To insure prompt repair under this Warranty, Pleasurecraft will maintain a supply of warranted parts suffi cient to meet the expected demand for such parts. Any replacement part may be used in the performance of any warranty maintenance or repairs and will be provided by Pleasurecraft without charge to the owner.
  • Page 12 INTRODUCTION - 1 This Page Was Intentionally Left Blank L510010-11...

  • Page 13: Safety Information

    U.S. Coast Guard approved, could cause a fi re 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).

  • Page 14: Boating Responsibilities

    BOATING RESPONSIBILITIES - 2 To fi nd out more about making boating safer, including CARBON MONOXIDE HAZARD 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 15: Safe Boating Suggestions

    • Signal devices: fl ares, spotlight, signal fl ag and • Power Squadrons horn or whistle. • Coast Guard Auxiliary • PCM Engines’ “Onboard Kit,” plus spare fuses, • Red Cross • State, provincial or local agencies in charge of bulbs, batteries, etc. Tools necessary for minor repairs.

  • Page 16: 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.

  • Page 17: Engine Identification

    OPERATION AND EVERY 100 HOURS OR 12 MFR DATE: MONTHS, WHICHEVER OCCURS FIRST. IMPORTANT NOTE: WARRANTY IS VOID IF MAINTENANCE AND LUBRICATION INSTRUCTIONS PER PCM MANUAL ARE NOT FOLLOWED. 3. TRANSMISSION IDENTIFICATION PLATE 2. ENGINE IDENTIFICATION DECAL Figure 3-1 Engine Identifi cation Decal...

  • Page 18: Engine Model Identifi Cation / Advisory

    ENGINE IDENTIFICATION - 3 ENGINE MODEL IDENTIFICATION / ADVISORY MODEL 0 2 - 6 0 2 V - 0 1 SERIAL 515000 Space: MANUFACTURING CODE *SERIAL NUMBER I.D.* Space: ENGINE CODE rd - DIGIT INDICATES DECADE ENGINE WAS 502 = HO303 MANUFACTURED ( 3 = 1990, 4 = 2000, 5 = 2010 ) 570 = EX343 DIGIT INDICATES CALENDAR YEAR ENGINE WAS...

  • Page 19: Electronic Fuel Injection Information

    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: •...

  • Page 20: Operating Instructions

    The alarm circuit has a “self” checking feature ENGINE ALARM SYSTEM 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.

  • Page 21: Instrumentation

    OPERATING INSTRUCTIONS - 5 INSTRUMENTATION CHECK Boat manufacturers install many different types of ENGINE instrumentation on boats. Become familiar with the VOLT instrumentation on your boat and be aware of abnormal 20 30 operating conditions. The following is a brief explanation of typical instrumentation found on most boats: 1.
  • Page 22 IT IS PCM has introduced a product enhancement feature on all PCM Mulitport Fuel Injection Products. Your engine RECOMMENDED THAT UNCOVERED ENGINE may be equipped with the engine auto-crank feature.

  • Page 23: Shifting Transmission

    CAUTION before attempting to restart the engine. Never shift the transmission into or out of gear NOTICE: If engine still fails to start, contact your PCM unless the throttle is at the idle position. Shifting the Engines Dealer for service.

  • Page 24: 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 and the must be protected after the engine is shut off to prevent transmission to Neutral.

  • Page 25: Pcm Basic Cruise Speed Control System

    When the Basic Cruise System is operated in the MPH Mode, the operator will select the desired boat speed he Figure 5-4 PCM Basic Cruise Control Panel (Typical) wishes to maintain. Boat speed information is provided information is monitored by the ECM, and is the same to the ECM via the paddle wheel.

  • Page 26: Operating Instructions

    (MPH or RPM) has been cancelled. At this point, a new set speed Figure 5-4 PCM Basic Cruise Control Panel (Typical) could be selected, you may use the Resume Mode to go back to the previous set speed, or you could change Lamp will be off.

  • Page 27: 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 28: Propeller Selection

    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.

  • Page 29: 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: PCM Engines assumes no responsibility for CAUTION the costs related to the 25-hour inspection. This is the owner’s responsibility.

  • Page 30: 25-Hour Engine Inspection

    After the fi rst 25 hours of operation, it is recommended that the engine be given an inspection. Your boat dealer or a PCM Premier servicing dealer should be contacted to perform the necessary checks and adjustments to ensure the proper engine performance. The following maintenance should be performed: •...

  • Page 31: Fuel Requirements

    87 octane fuel rating. PCM’s stalling, and shortened fuel shelf life. engine control module incorporates Adaptive Learn •...

  • Page 32: Oil Requirements

    PCM Engines does not review, approve or • Initial oil change - 1st 60 days or 25 hours of recommend such products.

  • Page 33: Engine Maintenance

    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...
  • Page 34 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 fl uid requirements can be different between these could be sprayed from the dipstick hole.

  • Page 35: Lubrication

    Hot transmission fl uid could be sprayed from the hole. BALL JOINT All PCM Power-Plus “V” Drive transmissions are designed to be ‘Maintenance Free’. Inspect fl uid CABLE level after the fi rst 25 hours of use and annually CLIP thereafter.

  • Page 36: Electrical System Relay And Fuse Block

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

  • Page 37: Fresh Water Cooling System Sacrifi Cial Zinc Anode

    ENGINE MAINTENANCE - 11 FRESH-WATER COOLING SYSTEM WARNING SACRIFICIAL ZINC ANODE Hydrogen gases that escape from the battery when Located in the raw water side of the heat exchanger is charging are highly explosive. Do not use jumper a zinc anode which is marked by a decal. To check, cables and a booster battery to start the engine.

  • Page 38: Checking Coolant Level

    ENGINE MAINTENANCE - 11 CHECKING COOLANT LEVEL CAUTION WARNING Do not run the engine above 1500 RPM when fl ushing. Suction created by the sea-water pump Do not remove cooling system fi ller cap when the may collapse the fl ushing hose, causing the engine engine is hot.

  • Page 39: Draining Fresh-Water Cooling System

    ENGINE MAINTENANCE - 11 1. Obtain red litmus paper from a local supplier (drugstore, laboratory, etc.). 2. Remove the pressure cap from the coolant fi ller neck and insert one end of the litmus paper into the coolant. 3. If red litmus paper turns blue, coolant is alkaline and does not need to be replaced.

  • Page 40: Filling Fresh-Water Cooling System

    ENGINE MAINTENANCE - 11 FILLING FRESH-WATER COOLING SYSTEM ANTIFREEZE (Non-Catalyst and Half-System Applications) SOLUTION A new extended life engine coolant known as DEX- COOL™ is used in your engine(s). It is imperative to note the following about DEX-COOL™ engine coolant: •...
  • Page 41 ENGINE MAINTENANCE - 11 FILLING FRESH-WATER COOLING SYSTEM (ZR409 CES / ZR450 CES Full-Fresh Applications) 1. If the system contains a heater, close both ball valves. Disconnect both hoses from the ball valves and plug hoses to prevent leakage. 2. First, raise the degas bottle from the lower, or running location, to the upper, or fi...
  • Page 42 ENGINE MAINTENANCE - 11 3. Remove the cap from the degas bottle. Open the heat exchanger bleed valve and keep fi lling until solid liquid is achieved from the drain hose. Note: Make sure the drain hose is uncoiled and fl owing freely. Note: A plug may have to be removed from the end of the drain hose.

  • Page 43: Cleaning Sea-Water Section Of Heat Exchanger (Fresh-Water Cooled Applications Only)

    ENGINE MAINTENANCE - 11 11. Return the degass bottle to the lower, or running position. Make sure the bottle level is at the “Min” mark on the bottle and tighten the cap. Lower Location Upper Location Important: If a heater is used, the complete heater system, hoses and core, should be prefi lled by either pumping or sucking Dexcool through the system.

  • Page 44: Fuel System Description

    The FCC system incorporates two (2) fuel pumps to the fuel system and/or replacing fuel fi lter. Gasoline provide an uninterrupted fl ow of fuel to your PCM marine is extremely fl ammable and highly explosive under engine. Fuel is fed into the FCC bowl by a low-pressure, certain conditions.

  • Page 45: Servicing The Fcc

    ENGINE MAINTENANCE - 11 FUEL SUPPLY LINE FUEL RETURN LINE 5.0/5.7L RETURN ONLY FUEL FUEL CONTROL TANK CELL FROM FUEL TANK LOW-PRESSURE FUEL PUMP PRIMARY Fuel / Water Separating Filter Element Part Number R077019 FUEL Manufacture Date 10/03/09 Tested To ISO, SAE, and JIC Standards at 5 PSI WARNING-PRESSURIZED GASOLINE FUEL SYSTEM-FIRE HAZARD PRE-FILTER To Replace Filter Element:...
  • Page 46 ENGINE MAINTENANCE - 11 Draining the FCC Bowl, ENGINE OFF 1. Disconnect the two-wire electrical connectors from the FCC and the Low Pressure Fuel Pump 6.0L 5.0/5.7L (LPFP). 2. Remove the 7/16” plug, and drain the bowl contents into an approved container. O-RINGS FUEL PRESSURE...

  • Page 47: Servicing Fuel Pre-Filter

    ENGINE MAINTENANCE - 11 15. Reconnect the fuel supply line to the LPFP. Filter Element Replacement, ENGINE OFF 16. Reconnect the two-wire electrical connectors to PRIMARY FUEL PRE-FILTER #: R077019 (SPIN- the FCC and the LPFP. 17. Cycle the ignition key several times to run the NOTE: This fi...

  • Page 48: Flame Arrestor

    ENGINE MAINTENANCE - 11 FLAME ARRESTOR ACCESSORY DRIVE BELT PCM engines use a single serpentine belt to drive the At specifi ed intervals, the fl ame arrestor should be engine water circulation pump, sea-water pump and the checked for blockage caused by dirt or other foreign alternator.

  • Page 49: Servicing Raw Water Pump Impeller

    ENGINE MAINTENANCE - 11 Belt Alternator Tensioner Idler Belt Tensioner Circulation Raw Water Pump Pump Circulation Pump Raw Water Pump Alternator Crankshaft Pulley Crankshaft Pulley Figure 11-19 5.0/5.7L Accessory Drive Belt Confi guration Figure 11-17 6.0L Accessory Drive Belt Confi guration Figure 11-18 Belt Tensioner (6.0L) Figure 11-20 Belt Tensioner (5.0/5.7L) SERVICING RAW WATER PUMP IMPELLER...

  • Page 50: Changing Oils

    CONTAINER The transmission oil change should be performed by an authorized PCM Premier dealer, at specifi ed intervals. Figure 11-21 Engine Oil Removal Transmission fl uids should be removed through a copper tube, that extends to the bottom of the transmission case, using a suction/vacuum type fl...

  • Page 51: Engine Alignment

    2. Center the propeller shaft in the shaft log as The Transmission support mounts must be removed follows: (Figure 11-25) before performing the engine alignment. Alignment is achieved using the Engine front mounts and the PCM • Push down and then lift the propeller shaft as V-Drive rear mounts.
  • Page 52 ENGINE MAINTENANCE - 11 .003 INCH (0.07 mm) TRANSMISSION FEELER GAUGE OUTPUT FLANGE PROPELLER SHAFT COUPLING FLANGE 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.
  • Page 53 ENGINE MAINTENANCE - 11 • LEFT or RIGHT ADJUSTMENT: Loosen .003 INCH the trunnion clamping bolt and the nut on all (0.07 mm) four mounting brackets. Move the engine TRANSMISSION FEELER GAUGE to the left or right, as necessary, to obtain OUTPUT FLANGE the proper alignment.
  • Page 54 ENGINE MAINTENANCE - 11 Angular Misalignment Front Mount Adjusted Both Trunnion • 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.

  • Page 55: Engine Maintenance Log

    ENGINE MAINTENANCE - 11 ENGINE MAINTENANCE LOG Operating Date Maintenance/Repair Hours L510010-11...

  • Page 56: 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 57: Maintenance Schedule

    (A) Use SAE 30 engine oil In fresh-water areas, every 50 hours of operation or (B) All PCM, Velvet Drive and Hurth transmissions - Use 60 days (whichever occurs fi rst). In salt-water areas, Dexron III automatic transmission fl uid every 25 hours of operation or 30 days (whichever occurs fi...

  • Page 58: Visual Inspection

    2 - Refer to the Checking Fluid Levels instructions pages 30-31 of this manual for complete instructions for checking transmission fl uid levels. IMPORTANT: Fluid levels on the PCM 1:1 and 1.23:1 transmissions are checked while the engine is running. All other transmission fl uid levels are checked at operating temperature and immediately after shutdown of the engine.

  • Page 59: Filter And Accessory Requirements

    Install filter turning it clockwise until hand tight plus 2/3 to 1 turn. P/N R143213 R077019 PCM POWER-PLUS V-DRIVE LUBRICANT Description Part No. PCM Power-Plus V-Drive Lubricant (1 qt. bottle) R190250 PCM BASIC CRUISE SPEED CONTROL SYSTEM Description Part No. PCM Basic Cruise Control Panel...

  • Page 60: Engine Specifications

    ENGINE SPECIFICATIONS - 12 PCM MASTER ENGINE SPECIFICATIONS - 2011 MODEL CES/MPI HO303 CES/MPI EX343 CES/MPI ZR409/ZR450 5.0L (305 CID) 5.7L (350 CID) 6.0L (366 CID) Displacement 3.75 in. (95.0 mm) 4.0 in. (101.6 mm) 4.0007 in. (101.618 mm) Bore 3.48 in.
  • Page 61 ENGINE SPECIFICATIONS - 12 L510010-11...

  • Page 62: Engine Specifications

    ENGINE SPECIFICATIONS - 12 6.0 Liter 5.0 / 5.7 Liter LH ROTATION LH ROTATION FRONT FRONT DISTRIBUTOR 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 ALL HO303 ALL ZR409 Model ALL EX343...

  • Page 63: Out-Of-Season Storage

    WARNING IMPORTANT: This service should be performed by Operate the bilge blower and be sure no fuel vapors an Authorized PCM Premier dealer. are present when treating the engine. Be sure the engine compartment is well-ventilated to prevent a potential fi re hazard.

  • Page 64: Draining Instructions

    BATTERY STORAGE Follow the battery manufacturer’s instructions for IMPORTANT: These services should be performed storage. If not available, use the following instructions: by an Authorized PCM Premier dealer. • Remove the battery from the boat and clean, CAUTION removing dirt and grease from the top of the battery.

  • Page 65: Recommissioning After Storage

    9. Refer to the OPERATING INSTRUCTIONS IMPORTANT: These services should be performed section and perform all the safety checks by an Authorized PCM Premier dealer. before starting the engine. When recommissioning the engine after storage, the 10. Refer to the Engine Maintenance section...

  • Page 66: 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 PCM Engines Servicing Dealer for assistance. Malfunction Possible Cause Corrective Action Problem with the engine...
  • Page 67 TROUBLESHOOTING - 14 Malfunction Possible Cause Corrective Action Loose or worn drive belt(s) Adjust or replace the belts as Engine Overheats 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 68: Troubleshooting

    Contaminated fl uid Determine and correct the contamination source and change the fl uid. Ignition system malfunction Contact PCM Engines Dealer. Engine misses, runs rough and/or backfi res Plugged fuel fi lters Replace the fuel fi lters. Faulty fuel pump.

  • Page 69: Raw Water Flow Diagrams

    WATER FLOW DIAGRAMS - 15 Figure 15-1 Direct Drive Raw-Water Cooling System HO303 / EX343 L510010-11...
  • Page 70 WATER FLOW DIAGRAMS - 15 Figure 15-2 Vee Drive Raw-Water Cooling System HO303 / EX343 L510010-11...
  • Page 71 WATER FLOW DIAGRAMS - 15 Figure 15-3 Direct Drive Half-System HO303 / EX343 L510010-11...
  • Page 72 WATER FLOW DIAGRAMS - 15 Figure 15-4 Vee Drive Half-System HO303 / EX343 L510010-11...
  • Page 73 WATER FLOW DIAGRAMS - 15 Figure 15-5 Direct Drive CES HO303 / EX343 L510010-11...
  • Page 74 WATER FLOW DIAGRAMS - 15 Figure 15-6 Vee Drive CES HO303 / EX343 L510010-11...
  • Page 75 WATER FLOW DIAGRAMS - 15 Note: This diagram is for illustration purposes only. The actual routing and/or shape of the hoses may vary slightly depending on installation. Drain Locations - Transmission Cooler - Remove Inlet Hose - Raw Water Pump - Remove Outlet Hose - Heat Exchanger - Remove Drain Plug/Zinc Anode - Exhaust Manifolds - Remove Drain Plugs Figure 15-7 Direct Drive Fresh-Water Cooling System ZR409 / ZR450...
  • Page 76 WATER FLOW DIAGRAMS - 15 Figure 15-8 Vee Drive Fresh Water Cooling System ZR409 / ZR450 L510010-11...
  • Page 77 WATER FLOW DIAGRAMS - 15 Figure 15-9 Direct Drive Full-Fresh ZR409 CES / ZR450 CES L510010-11...
  • Page 78 WATER FLOW DIAGRAMS - 15 Figure 15-10 Vee Drive Full-Fresh ZR409 CES / ZR450 CES L510010-11...
  • Page 79 WATER FLOW DIAGRAMS - 15 Figure 15-11 Direct Drive Half-System ZR450 CES L510010-11...
  • Page 80 WATER FLOW DIAGRAMS - 15 Figure 15-12 Vee Drive Half-System ZR450 CES L510010-11...

  • Page 81: Heater Connections

    HEATER CONNECTIONS - 16 WATER OUT Remove plug from intake manifold and install proper barbed fi tting. The plug is located toward the front of the intake (belt end) on the even cylinder side. WATER RETURN Remove plug from circulation pump and install proper barbed fi...

  • Page 82: Heater Connections

    HEATER CONNECTIONS - 16 WATER OUT Remove plug from supplied ball valve fi tting and install proper barbed fi tting. The fi tting is located in the hose above the heat exchanger on both CES and non-catalyst engines. 6.0L Catanium Exhaust System (CES) 6.0L Non-Catalyst WATER RETURN Remove plug from supplied ball...

  • Page 83: Instrumentation Wiring Diagram

    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. ENGINE 2-PIN WIRE HARNESS COLOR CHART HARNESS CIRCUIT CIRCUIT...

  • Page 84: Literature

    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.

  • Page 85: Forms

    IMPORTANT! PURCHASER NOTICE: The checks listed below are designed to insure safety and satisfaction. A step-by-step procedure for pre-delivery can be found in Course 1 of the PCM E-Train Program. Therefore, we require the following inspection be performed at your expense by a qualifi ed technician prior to delivery.
  • Page 86 SUMMARY OF WARRANTY TERM LIMITS This list does not, in any way, modify the offi cial Limited Warranty Statement of PCM. This list has been compiled only as a general outline of year and hour limits imposed on different models of PCM engines. Please review the offi cial Limited Warranty Statements on the following pages for specifi...
  • Page 87 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 Check Lay Up Launch Runs Made Date Fuel Port...

  • Page 88: Forms

    FORMS - 19 PROBLEM NOTIFICATION OR INFORMATION REQUEST FORM IMPORTANT: All blanks MUST be completed to insure proper identifi cation of your engine which is necessary to properly understand your request. When completed, mail this form to: Pleasurecraft Marine PO Drawer 369 Little Mountain, SC 29075 Engine Model Engine Serial Number...

  • Page 89: Notes

    NOTES - 20 L510010-11...
  • Page 90 Date of Sale or user’s sole remedy in the event of breach of the warranties which are made by PCM is repair or replacement of the product or any warranted part thereof as set forth herein: with this sole exception, PCM shall not be liable for any direct, or indirect, incidental or consequential damages, including without limitation, any damages for property damage, loss of use or loss of profi...
  • Page 92 This Page Was Intentionally Left Blank...
  • Page 93 Pleasurecraft Engine Group 1737 Highway 76 East, Little Mountain SC 29075...

This manual is also suitable for:

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