Crusader Carb. 5.7L Product Installation Manual Download Page 1

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E N G I N E S

PRODUCT

INSTALLATION MANUAL

03/07

L510023-07

Retail Price $12.00

Summary of Contents for Carb. 5.7L

Page 1: ...E N G I N E S PRODUCT INSTALLATION MANUAL 03 07 L510023 07 Retail Price 12 00 ...

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Page 3: ...able multifunction digital displays such as PowerView and HelmView plus a complete line of CAN Bus Instrumentation that are completely compatible with your new Crusader engine The Crusader Engines ECM 07 engine management system outputs J1939 and NEMA 2000 protocol messages that may be compatible with other manufacturers multifunction display equipment Check with the manufacturer of the display an...

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Page 5: ...ons 18 Crusader Classic Installation Accessories 18 Crusader Classic Engine Wiring Diagram 19 Boat Adapter Harness Diagram 20 Engine Boat Harnesses and Accessories Diagram 21 Crusader Boat Harness Wiring Diagram 22 Engine Speed Control CAN Bus Harness Diagram 23 Sync Cruise Switch Panel Wiring Diagram 24 Crusader Boat Speed Control Harness Wiring Diagram 25 Engine Compartment Ventilation 26 Fuel S...

Page 6: ...CH HURTH 630 8 DOWN ANGLE 62 5 7L BOSCH HURTH 630V 63 5 7L BOSCH VELVET DRIVE 72 DIRECT DRIVE 64 6 0L W 4 IN RISERS HURTH 630 8 DOWN ANGLE 65 8 1L HURTH 630A 8 DOWN ANGLE 66 8 1L VELVET DRIVE 72 DIRECT DRIVE 67 8 1L VELVET DRIVE 72 REDUCTION 68 CRUSADER XL SERIES INSTALLATION DRAWINGS 350XL HT WITH HURTH V DRIVE GEAR 69 350XL HT WITH VELVET DRIVE 5000V GEAR 70 350XL HT WITH HURTH SERIES 8 DOWN ANG...

Page 7: ...roducts manufactured and marketed by Crusader Engines That they have been trained in the recommended installation procedures of these products which includes the use of mechanics common hand tools and any recommended tools from other manufacturers We could not possibly know of and advise the marine trade of all conceivable procedures by which an installation might be performed and of the possible ...

Page 8: ... 6 0 0 V 0 1 SERIAL 670000 SERIAL NUMBER I D 1st DIGIT INDICATES DECADE ENGINE WAS MANUFACTURED 5 1990 6 2000 7 2010 2nd DIGIT INDICATES YEAR ENGINE WAS MANUFACTURED 1st 2nd Space MANUFACTURING CODE 3rd 5th Space ENGINE CODE 810 8 1L 496 CID LH MPI GM 811 8 1L 496 CID LH H O MPI GM 600 6 0L 364 CID LH MPI GM 570 5 7L 350 CID LH MPI GM 571 5 7L 350 CID RH MPI GM 572 5 7L 350 CID LH Carburetor GM 57...

Page 9: ...5 L510023 07 Figure 2 Engine Applications Typical 8 Degree Down Angle Transmission Figure 3 Engine Applications Typical V Drive Transmission ...

Page 10: ... output ﬂange rotation decal is critical as operating the transmission in Reverse to move the boat forward WILL CAUSE transmission failure The transmission MUST BE operated in forward gear only to propel the boat forward Figure 5 Standard Velvet Drive Identiﬁcation Plate and Propshaft Rotation Figure 6 Shift Lever Positions Standard Velvet Drive PROP SHAFT ROTATION DECAL IDENTIFICATION TAG TOWARD ...

Page 11: ...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 Transmission gear ratio and serial number is marked on the transmission identiﬁcation plate LH RH FORWARD GEAR FORWARD GEAR VELVET DRIVE 5000 TRANSMISSIONS RH PROP SHAFT ROTATION LH PROP SHAFT ROTATION LH RHFORWARD GEAR FORWARD GEAR RH PRO...

Page 12: ...n the Master Engine Speciﬁcations found within this manual Because of many variables of boat designs only testing will determine the best propeller for a particular application A propeller should be selected that will allow the engine to operate at or near the recommended WOT operating range with a normal load Refer to the engine RPM chart right or the Master Engine Speciﬁcations found in this man...

Page 13: ...7 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 Figure 9 Single Engine Velvet Drive in Line Installation 1 1 1 52 1 2 57 1 or 2 91 1 Ratio LH FRONT LH OR CCW ENGINE ROTATION FLYWHEEL ...

Page 14: ...ller Figure 10 Single Engine Velvet Drive in Line Installation 1 90 1 Ratio Single Engine V Drive Installation The transmission output shaft rotation is the opposite of the engine rotation A LH CCW rotation engine requires a RH propeller Figure 11 Single Engine V Drive Installation RH FRONT LH OR CCW ENGINE ROTATION FLYWHEEL FLYWHEEL LH OR CCW ENGINE ROTATION FRONT INPUT GEAR ROTATION OUTPUT FLANG...

Page 15: ...ion Dual Engine Velvet Drive 5000 and Hurth 630V V Drive Installation These Full Reversing V Drive transmissions rotate equally in either direction depending upon shift lever position and desired propeller rotation Velvet Drive 5000 V Drive gear ratios include 1 21 1 1 51 1 1 99 1 or 2 50 1 Hurth 630V gear ratios include 1 30 1 1 55 1 2 00 1 or 2 50 1 Figure 13 Dual Engine Velvet Drive 5000 and Hu...

Page 16: ...ON REQUIREMENTS Battery Battery Cables IMPORTANT Boating industry standards BIA ABYC etc Federal standards and Coast Guard regulations must be adhered to when installing the battery Be sure the battery cable installation meets the pull test requirements and that the positive battery terminal is properly insulated in accordance with the regulations IMPORTANT Engine electrical system is negative gro...

Page 17: ...re defective and need to be replaced Refer to pages 20 and 25 for replacement boat harnesses adapter harnesses and Sync N Cruz Speed Control Harness FWMurphy Instrument interface Crusader Engines are equipped with the ECM 07 engine management system This system outputs J1939 and NEMA 2000 protocol messages that may be utilized by various manufacturers of multifunction displays such as FWMurphy s C...

Page 18: ...e connection are Allows for twin engine Sync N Cruz operation Electronic Engine Monitor systems installed at the helm area may display engine data for both engines IMPORTANT In dual engine applications the master slave wiring harness is used to connect the engines together One end of this harness has one more wire in it than the other end The end with the extra wire is plugged into the Slave engin...

Page 19: ...ER TEMP OIL PRESS CHK ENGINE TRANS TEMP ENGINE HARNESS ENGINE HARNESS Part Number RA121093 Master Slave Engine Harness Part Number RA121072C PORT SLAVE ENGINE GND STARBOARD MASTER ENGINE Existing Boat Harness Existing Boat Harness PIN B TAN RED SPLICE TO TAN BLACK IN RA121093 PIN A ORANGE TAN SPLICE TO GREEN YELLOW IN RA121093 CUT 8 PIN CONNECTOR OFF HARNESS CUT 8 PIN CONNECTOR OFF HARNESS PIN B T...

Page 20: ...ss Figure 18 ECM Slave Ground Terminal Figure 20 Electrical System Connectors SLAVE ENGINE GROUND TERMINAL TO SLAVE ENGINE GROUND STUD TO SLAVE ENGINE TO MASTER ENGINE SPEED CONTROL CAN BUS CONNECTOR FUEL TANK SOLENOID CONNECTOR TWIN ENGINE MASTER SLAVE CONNECTOR 2 PIN BOAT HARNESS CONNECTOR 8 PIN BOAT HARNESS CONNECTOR INSTALLATION NOTE When installing the Optional Crusader Sync N Cruz system the...

Page 21: ... PLUG 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 8 PIN WIRE HARNESS COLOR CHART NOTE The MIL or Malfunction Indicator Lamp may be labeled the Check Engine Lamp on the instrument panel Check the boat owners manual for exact labelling Figure 20A Electrical System Connectors INSTALLATION NOTE When installi...

Page 22: ... CLASSIC 5 7L CARBURETOR ELECTRICAL SYSTEM PRECAUTIONS To avoid damage to the electrical system the following precautions must be observed when adding additional electric accessories DO NOT reverse battery leads DO NOT splice wires into engine electrical harness DO NOT puncture engine wires for testing probing DO NOT attempt engine diagnostics without the proper service tools DO NOT attach any acc...

Page 23: ...tion CAR BUR E TOR E LE CTR IC CHOKE MODULE PURPLE WHITE 14 ga Oil Pressure Fuel Pump Interlock S witch 5A Fuse RED 14 ga RED 14ga E LE CTR IC FUE L PUMP BLACK 14 ga BLACK 10ga 1 Ground To Carburetor Choke GROUND ENGINE BLOCK Low Oil Pressure S witch Water Temperature S witch E NGINE WAR NING CIR CUIT LT Green 14ga Not Used S tarter R elay 30 86 85 87A 87 FROM PIN 5 RED WHITE 16 ga R E D W H IT E ...

Page 24: ... a s h S i d e Boat Adapter Harnesses Part Number RA121093 Part Number RA121094 Part Number RA121094A Part Number RA121098 10 Pin Round Molded 8 Pin F 8 Pin M 14 Pin Merc Style Part Number RA121093A 10 Pin Round Molded W VDO Sensor leads ...

Page 25: ...s Buzzer Replacement Boat Harnesses Part Number RA121092 25 FT Unterminated RA121092A 45 FT Unterminated RA121092B 25 FT Terminated 8 Pin Connector RA121092C 25 FT W VDO Sender take outs Requires 2 harnesses one for each engine RK179008 Check Engine Lamp MIL Kit Lamp and Alarm Buzzer Requires 2 kits one for each engine NOTE The above illustration represents a typical twin engine installation using...

Page 26: ...d Boat Extension Harnesses RA121092 25 ft RA121092A 45 ft Extension harnesses are used to connect engine wiring to the helm 3 4 5 6 7 8 1 2 Coolant Temperature Sender Buzzer Ignition Feed Malfunction Indicator Lamp MIL Starter Circuit Oil Pressure Sender Battery Panel Power Ground Panel GRY 2 TACH RA121092_092A 9 28 06 Spliced at Helm by Installer ...

Page 27: ...attery Ground Sync Cruise Speed Cancel Set OFF ON Syn Cru Res Speed Battery Ground RA121091 25 FT Engine to Panel RA121091A 45 FT Engine to Panel Murphy HelmView OR Murphy PowerView NOTE The above illustration represents a typical twin engine installation using Crusader and Murphy harnesses Original boat harnesses may be used with the appropriate adapter and FWMurphy equipment may be used without ...

Page 28: ... Resistor Sync LED Cruise LED Circuit Board From Ignition To Ground Deutsch 12 Way Connector P N DT06 12S 9 10 12 11 3 8 Cruise LED Ground Sync LED Ground Cruise Request Sync Request Speed Set Cancel Speed Increment Decrement 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 thes...

Page 29: ...sses RA121091 25 ft RA121091A 45 ft 16 17 8 9 10 11 18 19 11 10 9 8 12 3 CAN 1 BUS CAN 1 BUS A B CAN 1 BUS CAN 1 BUS Cruise Request Speed Set Cancel Speed Increment Decrement Cruise LED Ground Sync Request Sync LED Ground Cruise Request Speed Set Cancel Speed Increment Decrement Cruise LED Ground Sync Request Sync LED Ground Deutsch 12 Way Connector P N DT04 12PA RA121091_091A 9 28 06 Twisted ...

Page 30: ...oubled for dual engine installations The pressure differential outside engine compartment versus inside engine compartment should not exceed 2 in 51 mm of water measured with a manometer at wide open throttle Engine Compartment Fuel Temperature Testing capable of operation throughout an ambient air temperature range from 20 to 150 F 7 to 65 C without failure Crusader EFI and associated components ...

Page 31: ...ne If a single pickup and line is used ﬁttings and line must not be smaller than 1 2 in 13 mm I D 3 Fuel tanks must have at least 1 2 in 13 mm shut off valves and ﬁttings on the fuel supply line and 3 8 in 10 mm shut off valves and ﬁttings on the fuel return line 4 There must be free ﬂow into the top of the tank for the return fuel line There must not be a dip tube extending into the tank 5 On ins...

Page 32: ...o minimize fuel temperature A Route all fuel lines as low in the bilge as possible to take advantage of the cooler ambient temperatures found there B Keep the use of brass fuel elbows and ﬁttings to an absolute minimum Brass is a good conductor of heat Tests have shown that fuel may begin to vaporize when passing through a 90 degree brass elbow at only 85 F 29 C ambient temperature C Maintain adeq...

Page 33: ... and service of the complete fuel system are required Any sign of fuel leakage or deterioration must be repaired immediately before further engine operation 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 lea...

Page 34: ...080033 This is a 3 piece RACOR fuel water separator This unit allows for the easy draining of water and contaminate inspection between service intervals without the need to replace the ﬁlter element during an inspection Crusader Engines recommends that the fuel water separator be mounted as low as possible relative to the fuel source away from heat such as exhaust runs and in an easily accessed an...

Page 35: ...tlets as possible 2 Not enough drop in the exhaust hose The most aggressive drop between the exhaust outlet and the mufﬂer or collector will aid in preventing condensation from forming and working its way back into the exhaust manifold s and elbow s A minus B must be this Engine Models distance or more All Engines 12 in 304 80 mm Figure 25 Proper Exhaust Elbow Location B A A FROM WATERLINE TO REFE...

Page 36: ...the engine exhaust elbow to the outlet with a minimum drop of 4 in 100 mm overall this is an ABYC recommendation The drop must be constant so that a low spot does not exist at any point in the exhaust hose or pipe Boating industry standards BIA ABYC etc Federal standards and Coast Guard regulations must be adhered to when designing and installing exhaust systems Figure 26 Exhaust Hose Connections ...

Page 37: ...must be connected to the engine exhaust elbows so that they do not restrict the ﬂow of discharge water from the elbow If hoses are connected incorrectly a hot spot in the hose can occur and eventually burn through 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 102 mm 4 in 102 mm MP 8 1L STD 4 in 102 mm 4 in 102 mm MP 8 1L HO...

Page 38: ...aust outlet s must be equipped with an internal shutter and or exhaust Boating industry standards BIA ABYC etc Federal standards and Coast Guard regulations must be adhered to when designing and installing exhaust systems ﬂapper to prevent seawater from running back into the exhaust system 5 System must not cause excessive back pressure Back pressure MUST NOT exceed 4 in 10 16 cm of mercury when m...

Page 39: ... IMPORTANT DO NOT install the water pickup directly in line with the propeller as the pickup may create turbulence and allow air to ﬂow into the propeller slipstream This will cause propeller ventilation and will adversely affect boat performance Figure 30 Water Pickup and Seacock SEACOCK SIZE RECOMMENDATION Seacock used must have an internal cross sectional area equal to or greater than the hose ...

Page 40: ...ut 50 lb ft 68 N m Exhaust Manifold Bolt 20 lb ft 27 N m PRELIMINARY ENGINE ALIGNMENT Mount Adjustment Tool P N 22165 1 Remove the lag screws holding the engine to the shipping pallet Attach a suitable sling to the lifting eyes on the engine Lift the engine from the pallet with an overhead hoist 2 Check the tightness of the engine mounts and re torque the mount attaching bolts to 45 50 lb ft 61 68...

Page 41: ...tment still exists on all four 4 mounts after performing ﬁnal adjustment This is necessary to allow for realigning the engine in the future 6 Check all four 4 mounts to ensure that they are still positioned properly then fasten the mounts to the engine bed with 1 2 in 1 27 cm diameter lag bolts of sufﬁcient length Tighten the lag bolts securely 7 Disconnect the overhead hoist and remove the sling ...

Page 42: ...e middle of the movement C With the propeller shaft in the middle of the shaft log align the engine to the shaft 3 Check that the coupling center lines align by butting the propeller shaft coupling against the transmission coupling The shoulder on the propeller shaft coupling face should engage recessed on the transmission coupling face with no resistance NOTICE Some propeller shaft couplings may ...

Page 43: ...o obtain the proper alignment IMPORTANT The large diameter of the mount trunnion MUST NOT extend over 1 0 in 25 4 mm from the mounting brackets on any of the mounts Figure 41 Engine Extension 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 speciﬁcat...

Page 44: ...ract the spring lock on the clevis pin and attach the shift cable to the ball joint stud 5 Place the remote control lever in the forward gear position and check the transmission shift lever position Lever must be positioned as shown for full engagement Figure 43 Shift Lever Positions Standard Velvet Drive TOWARD FLYWHEEL FOR FORWARD POPPET BALL F N R 4 Retract the spring lock on the clevis pin and...

Page 45: ...on Figure 46 Velvet Drive 5000 Shift Lever Movement vs Output Flange Rotation Figure 47 Shift Cable Installation Velvet Drive 5000 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 att...

Page 46: ... LH Prop Shaft Rotation Velvet Drive 5000 Figure 49 Forward Gear RH Prop Shaft Rotation Velvet Drive 5000 Attaching Adjusting Shift Cable Hurth 630 Series Transmissions These model transmissions are full reversing transmissions Rotation of the output ﬂange and propeller shaft is determined by the hookup of the shift cable at the remote control before starting the installation and adjustment proced...

Page 47: ...ement NOTICE If correct positioning is still not achieved the remote control does not provide sufﬁcient shift travel and must be replaced 8 Shift the remote control lever from forward to reverse and make sure cable moves freely and no binding occurs Figure 52 Forward Gear LH Prop Shaft Rotation Hurth Figure 53 Forward Gear RH Prop Shaft Rotation Hurth 1 Select a location for the audio warning buzz...

Page 48: ...d 1 Connect the engine positive battery cable usually red to the positive battery terminal 2 Connect the engine negative battery cable usually black to the negative battery terminal 3 Make sure that all the battery terminal connections are tight Then coat the connections and terminals with a battery terminal anti corrosion spray to help retard corrosion Figure 56 Battery Terminal Connections NEGAT...

Page 49: ...i 69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030009 R030009 R030011 R030010 Spark Plug Gap 0 060 in 0 060 in 0 060 in 0 060 in 0 060 in 0 060 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 8 7 2 6 5 4 3 LH 1 8 7 2 6 5 4 3 LH 1 8 4 3 6 5 7 2 LH 1 2 7 5 6 3 4 8 RH 1 2 7 5 6...

Page 50: ... F 235 F 10 F 235 F 10 F 235 F 10 F 235 F 10 F 235 F 10 F Over Temperature M I L DTC 1542 M I L DTC 1542 M I L DTC 1542 M I L DTC 1542 M I L DTC 1542 Check Gauges Lamp Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and or Buzzer Exhaust 248 F 5 F 248 F 5 F 248 F 5 F 248 F 5 F 248 F 5 F Over Temperature M I L DTC 2428 M I L DTC 2428 M I L DTC 2428 M...

Page 51: ... psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030009 R030009 R030011 R030010 Spark Plug Gap 0 060 in 0 060 in 0 060 in 0 060 in 0 060 in 0 060 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 8 7 2 6 5 4 3 LH 1 8 7 2 6 5 4 3 LH 1 8 4 3 6 5 7 2 LH 1 2 7 5 6 3 4 8 RH 1 2 7 5 6 3 4 8 RH N...

Page 52: ... F 235 F 10 F 235 F 10 F 235 F 10 F 235 F 10 F 235 F 10 F Over Temperature M I L DTC 1542 M I L DTC 1542 M I L DTC 1542 M I L DTC 1542 M I L DTC 1542 Check Gauges Lamp Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and or Buzzer Exhaust 248 F 5 F 248 F 5 F 248 F 5 F 248 F 5 F 248 F 5 F Over Temperature M I L DTC 2428 M I L DTC 2428 M I L DTC 2428 M...

Page 53: ... Proper Installation All Oil Lines Conﬁrm No Leaks Record Propeller Size Rotation and WOT Stbd WOT RPM_________Diameter_________ Pitch_________Rotation__________ Starboard Record Fuel Pressure WOT ______ Port Record Fuel Pressure WOT ______ NOTICE The following pages contain detailed steps in order to successfully perform the Crusader Pre Delivery Inspection Procedure These steps should be read ca...

Page 54: ...he model and serial number in the space provide The Crusader model identiﬁcation 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 Also the engine serial number This information will be needed for the next step...

Page 55: ...Problems associated with this fuel line or its installation should be corrected at the direction of the boat manufacturer and or installer and are not a Crusader Warranty item 5 Engine Wiring Inspection Do a visual inspection to insure that all plug in connectors of the engine wiring harness are plugged into their proper devices Check to insure that the boat harness is plugged completely and corre...

Page 56: ...rer dealer selects and installs the water exhaust hoses and accessories to the engine Problems associated with these hoses accessories or their installation should be corrected at the direction of the boat manufacturer and or installer and are not a Crusader Warranty item 8 Install and Tighten all Drain Plugs The drain plugs have been removed for shipping or winterization Before the engine may be ...

Page 57: ... cables and control head Check both the throttle and shift cable in accordance with the boat manufacturers and or installers instructions A minimum inspection of the control cables would include the following 1 Throttle and shift in neutral 2 Shift in forward throttle in neutral or idle position 3 Shift in reverse throttle in neutral or idle position and 4 Throttle at the wide open throttle WOT po...

Page 58: ...ted to to allow the fuel pumps to run until they shut off then turn the Ignition Switch to the OFF position Ignition switch must remain in the OFF position for a minimum of 5 seconds in order to reset the engine s ECM and allow another pump cycle to occur This procedure may have to be repeated 1 3 times to prime the fuel system Repeat as necessary to build fuel pressure to the speciﬁcation of this...

Page 59: ...ached to the engine NOTE Immediately proceed to the Transmission Fluid check after shutting the engines off False ﬂuid readings can be obtained as the ﬂuid returns to the transmission from the oil cooler and its lines Check the compliance box 4 Engine and Transmission Fluid Check Transmission On each transmission wipe the dipstick clean of oil and insert the dipstick into the dipstick opening Be s...

Page 60: ...te SUC 0706 01 for the procedure to be used to correct CAM Retard For Twin Engine Applications disconnect Diacom from the current engine and connect Diacom to the other engine Repeat the CAM Retard check adjustment for the other engine CAM RETARD Check the compliance box 6 Instrumentation Check The gauges on the boat s instrument panel are the operator s insight into the engine s vital signs Const...

Page 61: ...PMs have stopped increasing Note and record the fuel pressure at WOT for engine 2 Return to idle WOT RPM FUEL PRESSURE WOT 8 Diacom Record of Engine Performance Optional Record the following water test for your records using the Diacom Record feature This recording is to be made after all defects if any are found have been corrected The record time for this procedure will easily ﬁt on a 3 1 2 ﬂopp...

Page 62: ...ecord Fuel Pressure Port WOT Stbd WOT Belt and Pulley Inspect for Damage All Drain Plugs Conﬁrm Proper Installation All Fuel Lines Conﬁrm No Leaks All Oil Lines Conﬁrm No Leaks All Water Lines Conﬁrm No Leaks Electrical Wiring Check for Proper Installation Trouble Codes Checked Trouble Codes Cleared Your Diacom recording and these Pre Delivery procedure sheets can be archived either by engine seri...

Page 63: ...remaining dealer portion of the Crusader Warranty Registration form by ﬁlling in the following blocks Dealer Reviewed Warranty with Owner the last block of the Pre Delivery Checklist Dealer Signature By signing this form the dealer certiﬁes that he has checked the installation and operation of the engine s and ﬁnds them to be performing properly Owner s Signature and Date Give the customer their c...

Page 64: ...rement 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 The drop must be constant so that no low spots exist at any point in the exhaust hose The above are minimum guidelines for installation however meeting the minimum guidelines will not necessarily insure no water intrusion under all...

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Page 79: ...00 Fax 856 228 5657 Parts Fax 856 228 5531 Sales Engine Distributors Inc 400 University Court Blackwood NJ 08012 Jaime Cummins Phone 800 220 2700 Fax 856 228 5657 Parts Fax 856 228 5531 Sales Marysville Marine Distributors 1551 Michigan Avenue Marysville MI 48060 Steve Riehl Phone 810 364 7653 Fax 810 364 4112 Marysville Marine Distributors 127 Industrial Dr White House TN 37188 Randy Hall Phone 6...

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Page 81: ...E N G I N E S 11 06 L510023 APPENDIX A INSTALLATION DRAWINGS Captain s Choice and XLi SERIES Engines ...

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Page 83: ... VELVET DRIVE 72 V DRIVE A 17 454 XLI VELVET DRIVE 5000 8 DOWN ANGLE A 18 454 XLI VELVET DRIVE 5000 V DRIVE A 19 454 XLI HURTH 8 DOWN ANGLE A 20 454 XLI HURTH V DRIVE A 21 454 XLI DIRECT DRIVE A 22 454 XLI VELVET DRIVE 72 REDUCTION A 23 454 XLI VELVET DRIVE 72 V DRIVE A 24 454 XLI VELVET DRIVE DIRECT WITH INTEGRAL WALTERS A 25 502 XLI VELVET DRIVE 5000 A 26 502 XLI VELVET DRIVE 5000 V DRIVE A 27 5...

Page 84: ...ement 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 The drop must be constant so that no low spots exist at any point in the exhaust hose The above are minimum guidelines for installation however meeting the minimum guidelines will not necessarily insure no water intrusion under all ...

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Page 125: ...E N G I N E S APPENDIX B INSTALLATION DRAWINGS 11 06 L510023 XL SERIES ...

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Page 127: ...ANSMISSION B 14 CM305XL 5 0L CM350XL 5 7L BOBTAIL B 15 CM305XL 5 0L CM350XL 5 7L WITH WARNER DIRECT DRIVE TRANSMISSION 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 CM305XL 5 0L CM350XL 5 7L WITH WARNER DIRECT DRIVE A...

Page 128: ...ement 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 The drop must be constant so that no low spots exist at any point in the exhaust hose The above are minimum guidelines for installation however meeting the minimum guidelines will not necessarily insure no water intrusion under all ...

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Summary of Contents for Carb. 5.7L

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Crusader Carb. 5.7L, Product Installation Manual, Page: 1 / 157

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Summary of Contents for Carb. 5.7L

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