Crusader MP 5.0L Product Installation Manual
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Crusader MP 5.0L Product Installation Manual

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PRODUCT
INSTALLATION MANUAL
L510023-07
03/07
Retail Price $12.00

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Summary of Contents for Crusader MP 5.0L

  • Page 1 PRODUCT INSTALLATION MANUAL L510023-07 03/07 Retail Price $12.00...
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  • Page 3 Over the years, we have introduced many breakthrough innovations that quickly became industry standards. No matter which Crusader model you purchased, you can be sure it is equipped with the latest in modern technology for added performance and durability.

  • Page 5: Table Of Contents

    Engine Warning Kit (Optional) 14-15 …....…...…........……...……......Electrical System Precautions …......…....…...…...……...……..Engine Harness Electrical Connector Identifi cation …....….....……...……..Crusader Classic 5.7L Carburetor - Electrical System Precautions …....…..…...……...….....…..…...……..Crusader Classic Installation Accessories …....…..…...……...……......……..Crusader Classic Engine Wiring Diagram …....…........…...……...……...……...……..Boat Adapter Harness Diagram …....…..…...……...……...……...……..
  • Page 6 8.1L / HURTH 630A 8° DOWN ANGLE ....................8.1L / VELVET DRIVE 72 DIRECT DRIVE ...................... 8.1L / VELVET DRIVE 72 REDUCTION CRUSADER XL SERIES INSTALLATION DRAWINGS: ....................350XL-HT WITH HURTH V-DRIVE GEAR ..................350XL-HT WITH VELVET DRIVE 5000V GEAR ................

  • Page 7: General Information

    Loctite PST Pipe Sealant or equivalent installation procedures of similar products manufactured Mount Adjustment Tool - P/N 22165 and marketed by Crusader Engines. That they have been trained in the recommended installation procedures INSTALLATION DRAWINGS of these products which includes the use of mechanics’...

  • Page 8: Engine And Transmission Combinations

    Engine rotation is described by fl ywheel rotation viewing from the rear of the engine (transmission end) looking forward to the water pump end. Refer to the Crusader Model Identifi cation/Advisory information below. CRUSADER MODEL IDENTIFICATION /...
  • Page 9 Figure 2 Engine Applications - Typical 8 Degree Down Angle Transmission Figure 3 Engine Applications - Typical V-Drive Transmission L510023-07...

  • Page 10: Transmission Rotation

    Figure 4 Engine Applications - Typical Remote V-Drive Transmission TRANSMISSION ROTATION Velvet Drive In-Line and V-Drive Transmission gear ratio (in forward gear) is marked POPPET on the transmission identifi cation plate. Transmission BALL output shaft rotation is indicated on a decal on the transmission case.
  • Page 11 Velvet Drive 5000 Series and Hurth Transmissions These transmissions are “Full Reversing” with an 8-degree, down-angle output fl ange. This allows a standard (LH or CCW) rotation engine to be used for both propeller shaft rotations. Shaft rotation is determined by shift cable installation at the remote control (Figures 7 and 8).

  • Page 12: Gear Ratio Selection

    Minimum speed and transmission gear ratio. Fast boats operate Model Full Load Maximum Preferred best with direct drive or small reductions. Heavier boats MP 5.0L 4600 5000 4800 respond best with larger ratios of gear reduction. MP 5.7L 4800 5200...
  • Page 13 Single Engine Velvet Drive In-Line Installation - (1:1, 1.52:1, 2.57:1 or 2.91:1 Ratio) The transmission output shaft rotation is the same as the engine rotation. A LH (CCW) rotation engine requires a LH propeller. FRONT LH OR CCW ENGINE ROTATION FLYWHEEL Figure 9 Single Engine Velvet Drive in-Line Installation - 1:1, 1.52:1, 2.57:1 or 2.91:1 Ratio...
  • Page 14 INTRODUCTION - 1 Single Engine Velvet Drive In-Line Installation Single Engine V-Drive Installation - (1.90:1 Ratio) The transmission output shaft rotation is the opposite of the engine rotation. A LH (CCW) rotation engine The transmission output shaft rotation is the opposite requires a RH propeller.
  • Page 15 Dual Engine Velvet Drive 5000 and Hurth 630A Dual Engine Velvet Drive 5000 and Hurth 630V Installation V-Drive Installation These “Full-Reversing” transmissions rotate equally in These “Full-Reversing” V-Drive transmissions rotate either direction depending upon shift lever position and equally in either direction depending upon shift lever desired propeller rotation.

  • Page 16: Boat Construction

    BOAT CONSTRUCTION 1/2" x 6" LAG SCREW (MINIMUM LENGTH) Engine Bed The engine bed should be a horizontal type and rigid enough to maintain engine alignment at all times. Distance between the starboard and port engine mounts ADJUSTING is 22 1/2 in. (57.15 cm). The engine bed should support SLEEVE the four (4) engine mounts in such a manner so that a minimum of 1/4 in.

  • Page 17: Instrumentation

    ECM-07 diagnostic code CAUTION display, and much more. If a Crusader wiring harness is used, and a fused When replacing or installing the main boat harness, accessory panel is to be installed (30 amp current route the instrumentation wiring harness back to the...

  • Page 18: Master/Slave Wiring Connection

    Figure 17 Optional Warning Light Cluster - Crusader Part No. 23505 The Check Engine lamp, of the cluster, and Figure 16 Optional Warning Light / Alarm - Crusader the existing Buzzer may be used with ECM-07 Part No. RK179008 engine models.
  • Page 19 (2) Splice pin-A (Orange/Tan) to pin-6 of the respective engine 8-pin Deutsch connector and pin-B (Tan/Red) to pin-4 of the engine 8-pin connector. Only, the Check Engine Lamp and alarm buzzer of the warning cluster will be functional. Refer to the wiring diagram below for connection/splice options for the MIL and Buzzer.

  • Page 20: Electrical System Precautions

    TO SLAVE ENGINE INSTALLATION NOTE: When installing the GROUND STUD Optional Crusader Sync-N-Cruz system, the speed control harness (RA121091/RA121091A) MUST be connected to the Master engine, 20-Pin Speed Control/ CAN Bus Connector and the master/slave harness (RA121072C) must connect the Master and Slave engines together.

  • Page 21: Engine Harness Electrical Connector Identifi Cation

    Figure 20A - Electrical System Connectors INSTALLATION NOTE: When installing the Optional Crusader Sync-N-Cruz system, the speed control harness (RA121091/RA121091A) MUST be connected to the Master engine, 20-Pin Speed Control/CAN Bus Connector and the Master/Slave harness (RA121072C) must connect the Master and Slave engines together. Ensure that the Slave side of the harness is grounded to the Slave engine.

  • Page 22: Crusader Classic 5.7L Carburetor - Electrical System Precautions

    Adapter - Engine to Boat Harness R121073 ground location. 10-Pin to 8-Pin Female NOTE: Twin engine Sync-N-Cruz, multifuction displays, and CAN-Bus instrumentation options are not available with the Crusader Classic series engines. ENGINE HARNESS WIRE HARNESS COLOR CHART ADAPTER CIRCUIT...

  • Page 23: Crusader Classic Engine Wiring Diagram

    LT. Green 14ga Pigtail connector near 10-Pin connector Water T emperature Oil P res s ure S witch S witch E NG INE WAR NING C IR C UIT Figure 20B Typical Engine Wiring w/Mallory Ignition - Crusader Classic 5.7L Carburetor L510023-07...

  • Page 24: Boat Adapter Harness Diagram

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  • Page 25: Engine Boat Harnesses And Accessories Diagram

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  • Page 26: Crusader Boat Harness Wiring Diagram

    Crusader supplied Boat Extension Harnesses RA121092 = 25 ft RA121092A = 45 ft ***Extension harnesses are used to connect engine wiring to the helm. Spliced at Helm by Installer TAN/ GRN/ YEL/ Battery Ground TACH Coolant Buzzer Ignition Malfunction Starter...

  • Page 27: Engine Speed Control/Can-Bus Harness Diagram

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  • Page 28: Sync/Cruise Switch Panel Wiring Diagram

    Increment/ (Ground) (Ground) Cancel Decrement Deutsch 12-Way Connector P/N - DT06-12S Note: Panel 12-Way connector plugs directly into the following Crusader supplied Boat Speed Control Harnesses: RA121091 RA121091A ***See the following pages for schematics of these harnesses. RA152007 9-28-06 L510023-07...

  • Page 29: Crusader Boat Speed Control Harness Wiring Diagram

    Crusader supplied Boat Speed Control Harnesses RA121091 = 25 ft RA121091A = 45 ft Deutsch 3-Way Deutsch 12-Way Connector Connector P/N - DT04-12PA P/N - DT06-3S CAN 1 CAN 1 Speed Speed Cruise Sync Cruise Set/ Increment/ Sync Request Cancel...

  • Page 30: Engine Compartment Ventilation

    Engine compartment IMPORTANT: Crusader Engines will not honor any temperatures have been measured in excess of 200°F warranty claim for engine damage as a result of (82°C).

  • Page 31: Fuel Supply And Return Connections

    2. Dual installations; it is best to use a fuel pickup FUEL SUPPLY AND RETURN and supply line for each engine. If a single CONNECTIONS pickup and line is used, fi ttings and line must USCG & ABYC Standards not be smaller than 1/2 in. (13 mm) I.D. United States Coast Guard regulations (33 CFR Section 3.

  • Page 32: Fuel Inlet Restriction

    10 micron fi lter capability and a minimum of 90 gallons per hour fl ow rate, between the pump and fuel source. Crusader DOES NOT recommend the use of any additional fi lters installed by the OEM or boat dealer. The use of additional fi...

  • Page 33: Gasoline Requirements

    E10 IS NOT covered by the warranty. requirements listed below, is considered misuse of the engine. Such damage is not covered by the Crusader Marine Engines warranty. CAUTION The ignition timing set by the factory requires the use...

  • Page 34: Fuel Filter Recommendations For Ethanol Blended Fuel

    Crusader Engines recommends the R080033 - Fuel / Water Separator Replacement use of Crusader part number RA080033. This is a 3- Element piece, RACOR, fuel/water separator. This unit allows for RK080033 - Fuel / Water Separator Kit, Includes the easy draining of water and contaminate inspection RA080033 Assembly plus 1/2”...

  • Page 35: Exhaust System

    Damage caused by water entering the engine through EXHAUST RISERS the exhaust system WILL NOT be covered by Crusader To determine if exhaust risers are required, make the Engines Warranty, unless the damage is the result of following measurements.
  • Page 36 Exhaust Systems without Water-Lift Muffl ers 4. Exhaust outlet(s) should be slightly above the water line with the boat at rest in the water, and a full load onboard. Exhaust outlet(s) must be WARNING equipped with an internal shutter and/or exhaust fl...
  • Page 37 Minimum exhaust hose sizes are given can occur, and eventually burn through. in the chart below. MINIMUM EXHAUST HOSE SIZE Engine Single Dual MP 5.0L 4 in. (102 mm) 3 in. (76 mm) MP 5.7L 4 in. (102 mm) 4 in. (102 mm) MP 6.0L 4 in.
  • Page 38 If you have questions regarding the use of water-lift or pipe. muffl ers, contact Crusader Engines for clarifi cation. 4. Exhaust outlet(s) should be slightly above the water line with the boat at rest in the water, and a full load onboard.

  • Page 39: Throttle/Shift Remote Control And Cables

    THROTTLE/SHIFT REMOTE CONTROL AND CABLES 1.25 in (3.17 cm) Shift control and shift cable MUST position transmission INLET HOSE CONNECTION shift lever EXACTLY as stated in this manual or transmission failure may occur. Damage caused to transmission as a result of improper shift lever positioning WILL NOT be covered by transmission SEACOCK manufacturer’s warranty.

  • Page 40: Engine Installation

    2. Remove the bolt retaining the dipstick mounting PRELIMINARY ENGINE ALIGNMENT clamp. Then, remove the dipstick fi tting at the (Mount Adjustment Tool - P/N 22165) oil pan. Loosen the center bolt and rotate the oil 1. Remove the lag screws holding the engine to pan fi...

  • Page 41: Final Engine Alignment

    Velvet Drive and Hurth 8 Degree Down Angle All Transmissions Transmissions IMPORTANT: The engine bed must position the engine so that a minimum of 1/4 in. (6 mm) up-and- 5. Lift the engine into the boat and position it on down adjustment still exists on all four (4) mounts the engine bed so that the transmission and after performing fi...
  • Page 42 Figure 35 Shaft Mating Surface Check - V-Drives Figure 37 Centering Propeller Shaft - V-Drives 3. Check that the coupling center lines align by 2. Center the propeller shaft in the shaft log as butting the propeller shaft coupling against the follows: transmission coupling.

  • Page 43: Throttle/Shift Cables

    B. LEFT or RIGHT ADJUSTMENT: Loosen the trunnion clamping bolt and the nut on all four mounting brackets. Move the engine to the left or right, as necessary, to obtain the proper alignment. IMPORTANT: The large diameter of the mount trunnion MUST NOT extend over 1.0 in.
  • Page 44 2. Install the throttle cable hub into the throttle Attaching/Adjusting Shift Cable - Velvet Drive cable retaining clip and secure with the cable In-Line and V-Drive Models clip. IMPORTANT: Velvet Drive Transmission Warranty 3. Thread the ball joint clevis onto the throttle cable is jeopardized if the shift lever poppet ball or as far as necessary to line up the ball joint stud spring is permanently removed, if the shift lever...
  • Page 45 8. Shift remote control lever from forward to reverse and make sure cable moves freely and no binding occurs. FORWARD FORWARD GEAR GEAR PROP SHAFT ROTATION DECAL RH PROP SHAFT ROTATION LH PROP SHAFT ROTATION VELVET DRIVE 5000 TRANSMISSIONS IDENTIFICATION Figure 46 Velvet Drive 5000 Shift Lever Movement vs.
  • Page 46 5. Place the remote control shift lever in the forward Attaching/Adjusting Shift Cable - Hurth 630 gear position and check the transmission shift Series Transmissions lever position. Lever must be positioned as These model transmissions are full reversing shown for full engagement. transmissions.

  • Page 47: Audio Alarm System

    1. Place the remote control shift lever and transmission shift lever in neutral position. 2. Install the shift cable hub into the shift cable retaining bracket and lock the cable clip. 3. Thread the clevis pin onto the shift cable until the clevis lines up with the stud attached to the transmission shift lever.

  • Page 48: Exhaust System Connection

    EXHAUST SYSTEM CONNECTION CLASSIC 5.7L CARBURETOR - ENGINE HARNESS CONNECTION 1. Exhaust hoses must be connected to the exhaust elbows so that they do not restrict the Install the main engine electrical harness plug and clamp fl ow of discharge water from the elbow. If the as shown.

  • Page 49: Master Engine Specifi Cations

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  • Page 53: Delivery Preparation

    Dealer Reviewed Warranty Trouble Codes Checked with Owner Trouble Codes Cleared NOTICE: The following pages contain detailed steps in order to successfully perform the “Crusader Pre-Delivery Inspection Procedure.” These steps should be read carefully and completely prior to performing the inspection. L510023-07...

  • Page 54: Pre-Delivery Procedure

    Transmission Identifi cation location.) Locate the engine identifi cation tag and record the model and serial number in the space provide. The Crusader model identifi cation provides you with valuable information concerning the engine you are working on. Information includes raw/fresh water cooling, engine rotation, engine type, drive type and function, propeller shaft rotation, gear ratio, and ignition and fuel type.
  • Page 55 3. Propeller Identifi cation and Inspection (Refer to the Crusader Owner’s Operation and Maintenance Manual and the Crusader Master Engine Specifi cation Sheet for operational parameters based on propeller selection.) • Proper boat performance is dependent upon boat design, engine power and a properly sized propeller.
  • Page 56 STBD 9. Visual Check of Belt And Pulley Alignment NOTE: All Crusader engines currently use a serpentine belt at the front of the engine. This belt has a self-tensioning system which is non-adjustable. • Check belt for cuts or other damage. Correct any defi ciency.
  • Page 57 1006-01. Check the compliance box on the procedure. NOTICE: Improper adjustment of the control cables can cause engine and/or transmission damage. Control cables, their adjustment, or engine/ transmission damage resulting from improper adjustment are not a Crusader Warranty item. L510023-07...
  • Page 58 Stage 2 - Operational / Sea-Trial Inspection PORT STBD Boat-in-the-Water Tests IMPORTANT: Engine alignment MUST BE CHECKED at this time, with the boat in the water, fuel tanks fi lled, and with a normal load onboard. WARNING DO NOT leave the helm unattended while performing any tests. 1.
  • Page 59 PORT STBD 3. Engine at Idle Check Follow boat manufacturer’s starting procedures regarding the blower, etc. Start the engine. WARNING! If fuel and/or oil leaks are present shut off the engine(s) immediately. • Check to insure that the raw water pump is pumping water( both engines) then allow the engine(s) to idle for approximately one minute.
  • Page 60 A check of the engine management system is done to insure that the EFI system has not been damaged or modifi ed since shipment from Crusader. • With the Diacom loaded and set to Crusader’s standardized screen, turn the ignition switch(s) to the ‘ON’ position (Do Not start the engine(s)) and check the engine(s) for codes.
  • Page 61 7. Engine Performance Test • All gauges and test equipment should be observed as frequently as possible to allow the operator to react quickly to any discrepancy displayed. The operator must also listen for unusual sounds, feel for unusual vibrations, smell for signs of fuel, smoke, etc.
  • Page 62 Check the compliance box. 10. Complete the Pre-Delivery Checklist Obtain the Crusader Warranty Registration Form that came with the engine. Using the data obtained and recorded on the Pre-Delivery Inspection Procedure complete the following blocks on the Warranty Registration Form: Complete the Pre-Delivery Checklist by checking each box and fi...
  • Page 63 Address Boat Make, Length, Type You should review the Crusader 2 Year Transferable Limited Warranty with the new owner. Upon completion of the warranty review, you will complete the remaining dealer portion of the Crusader Warranty Registration form by fi lling in the following blocks.

  • Page 64: Exhaust System Installation Guidelines

    EXHAUST INSTALLATION GUIDELINES The top of the exhaust riser must be a minimum of 12 inches above the water line with the boat at rest and a full load aboard. It is recommended by the ABYC, and a Pleasurecraft Engine Group requirement, that there be a drop in the exhaust run between the engine and exhaust outlet of a minimum of 1 inch per foot of run, with a minimum of four (4) inches drop overall.

  • Page 65: Captain's Choice Installation Drawings: 5.7L Bosch / Velvet Drive 72 Reduction

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  • Page 79 CRUSADER MARINE ENGINES DISTRIBUTORS Marysville Marine Engine Distributors Inc. 400 University Court Engine Distributors Blackwood, NJ 08012 Jaime Cummins Engine Phone: 800-220-2700 Distributors Fax: 856-228-5657 - Parts Fax: 856-228-5531 - Sales Engine Distributors II jcummins@edi-dist.com Trans Pacific Engine Distributors Inc.
  • Page 81 APPENDIX - A INSTALLATION DRAWINGS Captain’s Choice XLi SERIES Engines 11/06 L510023...
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  • Page 83: L Bosch / Hurth 630 8° Down Angle

    INSTALLATION DRAWINGS: ............... EXHAUST SYSTEM INSTALLATION GUIDELINES CAPTAIN’S CHOICE INSTALLATION DRAWINGS: ................5.7L BOSCH / VELVET DRIVE 72 REDUCTION ................5.7L BOSCH / HURTH 630 8° DOWN ANGLE ..................... 5.7L BOSCH / HURTH 630V ................ 5.7L BOSCH / VELVET DRIVE 72 DIRECT DRIVE ..............
  • Page 84 EXHAUST INSTALLATION GUIDELINES The top of the exhaust riser must be a minimum of 12 inches above the water line with the boat at rest and a full load aboard. It is recommended by the ABYC, and a Pleasurecraft Engine Group requirement, that there be a drop in the exhaust run between the engine and exhaust outlet of a minimum of 1 inch per foot of run, with a minimum of four (4) inches drop overall.
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  • Page 127: 350Xl-Ht With Hurth V-Drive Gear

    B-16 ......CM305XL (5.0L) / CM350XL (5.7L) WITH WARNER REDUCTION TRANSMISSION B-17 CM305XL (5.0L) / CM350XL (5.7L) WITH WARNER DIRECT DRIVE AND CRUSADER 12° V-DRIVE B-18 ..CM305XL (5.0L) / CM350XL (5.7L) WITH WARNER DIRECT DRIVE AND WARNER 15° V-DRIVE B-19 ..
  • Page 128 EXHAUST INSTALLATION GUIDELINES The top of the exhaust riser must be a minimum of 12 inches above the water line with the boat at rest and a full load aboard. It is recommended by the ABYC, and a Pleasurecraft Engine Group requirement, that there be a drop in the exhaust run between the engine and exhaust outlet of a minimum of 1 inch per foot of run, with a minimum of four (4) inches drop overall.
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This manual is also suitable for:

Carb. 5.7l

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