PCM 2007 5.0L MPI Owner'S Operation And Maintenance Manual Download Page 4

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L510010-07A

Electrical System Relay and Fuse Block

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Electrical System Fuses

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Boat’s Ignition Fuse

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Electrical System Wiring and Connectors

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Battery

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Fresh Water Cooling System Sacriﬁ cial Zinc Anode

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Checking Coolant Level

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Flushing Cooling System - Sea-Water Section

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Testing Coolant For Alkalinity

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Draining Fresh-Water Cooling System

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Filling Fresh-Water Cooling System

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Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only)

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Fuel System Description

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Fuel Control Cell (FCC) Fuel System

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Servicing the FCC

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Primary Fuel Filter (FCC Clamp-on Canister)

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41-42

Servicing Fuel Pre-Filter

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Priming Fuel System

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Flame Arrestor

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Accessory Drive Belt

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44-45

Changing Oils

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Engine Alignment

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47-50

Engine Maintenance Log

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Maintenance Schedule

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52-53

Visual Inspection

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Engine Fluid Capacities

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Transmission Fluid Capacities

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Filter and Accessory Requirements

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ENGINE SPECIFICATIONS

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56-58

OUT-OF-SEASON STORAGE

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59-62

Engine Storage

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Draining Instructions

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Battery Storage

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Recommissioning After Storage

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TROUBLESHOOTING

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63-65

WATER FLOW DIAGRAMS

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66-69

INSTRUMENTATION WIRING DIAGRAM

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LITERATURE

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FORMS

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72-75

NOTES

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WARRANTY/REGISTRATION CARD

TABLE OF CONTENTS

Summary of Contents for 2007 5.0L MPI

Page 1: ...OWNER S OPERATION and MAINTENANCE MANUAL A Division of...

Page 2: ...ntrol Cell FCC are all PCM innovations No matter which PCM model you purchased you can be sure it is equipped with the latest in modern technology for added performance and durability READ THIS MANUAL...

Page 3: ...cation Advisory 14 ELECTRONIC FUEL INJECTION INFORMATION 15 Electronic Fuel Injection System 15 OPERATING INSTRUCTIONS 16 20 Electronic Speed Control 16 Engine Alarm System 16 Instrumentation 17 Star...

Page 4: ...ol Cell FCC Fuel System 40 Servicing the FCC 41 Primary Fuel Filter FCC Clamp on Canister 41 42 Servicing Fuel Pre Filter 43 Priming Fuel System 43 Flame Arrestor 43 Accessory Drive Belt 44 45 Changin...

Page 5: ...Survey We appreciate your feedback and encourage you to ll out the survey after you have had a chance to run your boat for several weeks We take this input very seriously and have implemented many of...

Page 6: ...rings and other material affected by time are not covered by this Warranty if their effectiveness is reduced by an extended storage period prior to sale or use OBTAINING PERFORMANCE UNDER WARRANTY PCM...

Page 7: ...g diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Select emission control parts from inboard marine engine manufactured from 2003 2007 are warranted for 2 years OWNER S WARRANTY RESPONSIBIL...

Page 8: ...asurecraft warranty station The repair or replacement will be per formed at no charge to the owner Any such part repaired or replaced under this Warranty will be warranted for the remainder of the two...

Page 9: ...gible for coverage under this Warranty may be excluded from such warranty coverage if Pleasurecraft demonstrates that the engine and or part has been abused neglected or improperly maintained and that...

Page 10: ...8 L510010 07A This Page Was Intentionally Left Blank INTRODUCTION 1...

Page 11: ...proved could cause a re or 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 DANGE...

Page 12: ...on reveals possible leaks DO NOT operate your engine s until it can be serviced by a quali ed technician Proper and adequate air circulation around and throughout the boat is absolutely necessary to a...

Page 13: ...seas whenever possible Follow the Rules of the Road when boating Always be on the alert and watch out for the other guy Plan and chart your course Be aware of and avoid hazardous areas Be sure your bo...

Page 14: ...the boat that are designed for that purpose If water is rough carry fewer passengers Observe the Rules of the Road PORT Left Leaving the harbor with green buoys to your right STARBOARD Right Entering...

Page 15: ...T STANDARDS FOR MARINE ENGINES IN EFFECT AT DATE OF MANUFACTURE LITTLE MOUNTAIN SC 29075 1 ENGINE SPECIFICATION DECAL 2 ENGINE IDENTIFICATION DECAL 3 TRANSMISSION IDENTIFICATION PLATE 3 2 2 1 OIL TYPE...

Page 16: ...Space MANUFACTURING CODE 3rd 5th Space ENGINE CODE 810 8 1L 496 CID MPI GM 811 8 1L 496 CID H O MPI GM 600 6 0L 364 CID MPI GM 570 5 7L 350 CID LH MPI GM 571 5 7L 350 CID RH MPI GM 572 5 7L 350 CID LH...

Page 17: ...to prevent engine damage from over revving The sensors that the ECM monitors are Engine Coolant Temperature ECT Sensor Throttle Position TP Sensor Manifold Absolute Pressure MAP Sensor Knock Sensor K...

Page 18: ...d or an optional audible alarm to warn the operator of possible engine problems The alarm circuit has a self checking feature programmed into the system This feature will momentarily light the MIL and...

Page 19: ...2 Water Temperature Gauge indicates the engine coolant temperature 3 Oil Pressure Gauge indicates the engine oil pressure 4 Voltmeter indicates the battery voltage and charging system voltage 5 Hour...

Page 20: ...tions on throttle shift lever operation IMPORTANT If the engine fails to start within 20 30 seconds turn the ignition key to the OFF position and allow 2 minutes for the starter motor to cool off befo...

Page 21: ...and determine the cause SHIFTING TRANSMISSION CAUTION Never shift the transmission into or out of gear unless the throttle is at the idle position Shifting the transmission above 1000 RPM can severely...

Page 22: ...Close the fuel valve 3 Close the seacock 4 Flush the cooling system if in a salt water area OPERATING INSTRUCTIONS 5 FREEZING TEMPERATURE OPERATION If the possibility of freezing exists the cooling s...

Page 23: ...s of the paddle wheel input With the engine off and the boat on a lift or the trailer inspect the paddle wheel for damage or blockage If you are unable to correct the problem at the paddle wheel conta...

Page 24: ...mp will go OFF Cruise mode will remain engaged until the operator pulls the throttle handle back below the set point IMPORTANT It is good practice to always exit Cruise Mode properly prior to shutting...

Page 25: ...cruising running against a choppy wave condition acceleration onto plane and operating at slow planing speeds Will improve rough water ride and handling In extreme may cause the boat to bow steer vee...

Page 26: ...ake into consideration are as follows Warmer weather and higher humidity will cause an RPM loss Operating the boat in a higher elevation will cause an RPM loss Operating the boat with an increased loa...

Page 27: ...complete safety CAUTION DO NOT operate at full throttle in neutral at any time or at sustained full throttle during the rst 5 hours of operation Thereafter use sustained wide open throttle in the even...

Page 28: ...rottle and the shift cable adjustments and check for freedom of movement Cooling System Inspect all the hoses for leaks damage and deterioration Check all the hose clamps for adequate tightness Exhaus...

Page 29: ...ections 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...

Page 30: ...perature Classi cation Viscosity Above 50 F SAE 15W 40 SM Below 50 F SAE 5W 30 SM IMPORTANT The use of oils which contain solid additives non detergent oils or low quality oils speci cally are not rec...

Page 31: ...es for the oil to drain back into the oil pan 2 Remove the dipstick wipe it clean and reinstall it until it is within two 2 inches of being fully seated Slowly move the dipstick up and down approximat...

Page 32: ...Remove the dipstick and check the uid level The dipstick should read FULL 5 If the uid level is low add in small increments until the FULL mark is reached 6 It is normal after the engine is turned OF...

Page 33: ...nance Free Inspect uid level after the rst 25 hours of use and annually thereafter Fluid should only be changed if evidence of contamination is present Use Mobiltrans SHC 50 synthetic transmission lub...

Page 34: ...l pump ECM ignition components fuel injectors starter and diagnostic devices are protected by fuses The fuse block is mounted on a bracket near the rear of the engine BOAT S IGNITION FUSE If the engin...

Page 35: ...engine with an open in the battery circuit as this may cause damage to the alternator Make sure that all connections are clean and secure When removing the battery cables always remove the negative ca...

Page 36: ...s gone replace with a new zinc anode Different geographic locations and water make up can result in either high or low sacri cial requirements A high rate of zinc anode consumption should also alert t...

Page 37: ...e severe burns Degas Bottle The see through degas bottle is connected to the heat exchanger by a small hose The degas bottle collects coolant that expands with rising temperature and would otherwise o...

Page 38: ...hose CAUTION Do not operate the engine without suf cient amount of water being supplied to the sea water pump The sea water pump impeller may be damaged and subsequent overheating damage may result F...

Page 39: ...fresh water cooling system Drain plug on oil cooler Drain plug on heat exchanger Drain plug on the bottom of each exhaust manifold 3 After system has drained completely coat all the drain plugs with...

Page 40: ...contamination occurs the cooling system must be immediately drained and ushed and re lled with DEX COOL No short term damage will occur however the service interval will be reduced from 5 years to 2 y...

Page 41: ...r repair facility 1 Remove the bolts securing the heat exchanger end plates Remove the end plates and gaskets 2 Clean the water passages in the heat exchanger by inserting a suitable size wire brush i...

Page 42: ...pump ows fuel at a volume much greater than the fuel ow rate required of the high pressure pump and engine demands The high pressure pump mounted inside the FCC bowl provides the necessary fuel pressu...

Page 43: ...ead and follow all instructions before proceeding Run the engine and check for fuel leaks after installation element replacement or draining the bowl DO NOT remove the FCC bowl unless servicing the lt...

Page 44: ...emove the old O rings from the FCC head CAUTION The mounting head O ring grooves may be damaged by using sharp steel tools to remove this O ring CAUTION Use only fuel approved O rings R047241 provided...

Page 45: ...ncy of replacing the lter element is determined by the contamination level of the fuel Replace the lter element at least once a year or when a loss of power is noticed whichever occurs rst WARNING Imp...

Page 46: ...0 are access holes in order to loosen the raw water pump attaching bolts The bolts are secured in the pump by O rings and will not fall out during removal Torque the raw water pump housing attaching b...

Page 47: ...al 4 Compress the belt tensioner and slide the belt over the tensioner pulley Release the tension slowly to tension the belt SERVICING RAW WATER PUMP IMPELLER 5 0 5 7L 5 0 5 7L IMPELLER KIT RP061022 T...

Page 48: ...e quick drain hose and insert the discharge hose into a suitable container Allow the oil from the engine to drain until the crankcase is empty Reinstall the cap onto the quick drain hose and pull the...

Page 49: ...nsmission mounts to achieve alignment The V Drive mounts are for support of the V Drive unit and are not used to achieve proper alignment PLEASURECRAFT ENGINEGROUP POWER PLUS RATIO 1 48 MADEINUSA TRUN...

Page 50: ...e 11 27 Figure 11 26 Shaft Mating Surface Check OFFSET MISALIGNMENT ANGULAR MISALIGNMENT PERFECT ALIGNMENT COUPLING FACES ARE PARALLEL WITH DISTANCE BETWEEN FACES EXACTLY THE SAME AT ALL POINTS Figure...

Page 51: ...a suf cient amount of the trunnion must remain in the mount to be secured by the trunnion locking bolt Figure 11 31 Angular Alignment STRAIGHT EDGE TRANSMISSION OUTPUT FLANGE 003 INCH 0 07 mm FEELER G...

Page 52: ...ing nut Turn the adjusting nut or the adjusting bolt in the direction required to raise or lower the engine After the adjustment is complete tighten the locking nut IMPORTANT If a pinch occurs in the...

Page 53: ...51 L510010 07A ENGINE MAINTENANCE 11 ENGINE MAINTENANCE LOG Operating Date Maintenance Repair Hours...

Page 54: ...impeller X X Drive Belt Inspect condition and check tension X X X Exhaust System Check condition and tightness of all hose clamps X X1 X Exhaust System Check for water leaks at the manifold riser and...

Page 55: ...section After use each day X Notes X Denotes service to be performed by the owner operator O Denotes service to be performed by an authorized PCM Engines dealer A Use SAE 30 engine oil B All PCM Velve...

Page 56: ...ilge have been purged If the boat is on a trailer the trailer must be level and adjusted to represent the boat s normal resting state on the water Oil capacities are approximate and may not include ca...

Page 57: ...mary Fuel Filter R080024 Fuel Control Cell FCC Fuel Filter Element RP080026 PCM BASIC CRUISE SPEED CONTROL SYSTEM Description Part No PCM Basic Cruise Control Panel RA152008 Speed Control Interface Ha...

Page 58: ...kPa 172 552 kPa Minimum Oil Pressure 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in Firing Order 1 8...

Page 59: ...6 M I L DTC 116 M I L DTC 116 Sensor Check Engine Lamp Check Engine Lamp Check Engine Lamp and or Buzzer and or Buzzer and or Buzzer Transmission 235 F 10 F 235 F 10 F 235 F 10 F Over Temperature M I...

Page 60: ...NG ORDER 1 8 7 2 6 5 4 3 FLYWHEEL END OF ENGINE ALL V 8 MODELS 1 7 c 6 4 2 8 3 5 Rotation TUNE UP SPECIFICATIONS Model MP 5 0L 275 HP MP 5 7L 343 HP MP 6 0L 390 HP Spark Plug Type R030010 R030011 Spar...

Page 61: ...he engine compartment is well ventilated to prevent a potential re hazard 2 Remove empty and clean the fuel lter assembly Reinstall with a new fuel lter and gasket seals Refer to Engine Maintenance fo...

Page 62: ...ENANCE If inspection proves the impeller to be in good condition store it in an accessible spot for re installation at the end of the storage period A damaged or badly worn impeller should be discarde...

Page 63: ...ne drain plug 2 Remove the hose from the inlet side of the sea water pump 3 Remove the hose from the outlet side of the sea water pump NOTICE It may be necessary to bend or lift the hoses to allow wat...

Page 64: ...ors sparks or open ame 3 Install the fully charged battery Be sure that all the connections are clean and free from corrosion Coat the battery terminal connections with an anti corrosion battery termi...

Page 65: ...connections starter circuit wiring Clean and tighten all connections Repair or replace the damaged wiring Dead Battery Recharge test and replace as necessary Engine Cranks will not Improper starting...

Page 66: ...e cooling system for leaks equipped with Fresh Water section of the cooling system Re ll the system See Warning Cooling FWC systems before removing the ll cap Heat exchanger passages plugged Clean and...

Page 67: ...Have fuel pump replaced by a PCM Engines Dealer Plugged or kinked fuel lines or Repair or replace the fuel lines fuel tank vent Remove obstruction Anti siphon valve faulty Clean or replace as necessa...

Page 68: ...ired at temp sender location Location 2 Water RETURN from heater or hot water tank Fitting at circulating pump 2 1 TO DRIPLESS SHAFT SEAL IMPORTANT The water supply hose to the Dripless Shaft Seal mus...

Page 69: ...R FLOW FRESH WATER FLOW Drain Locations 1 2 2 IMPORTANT Accessory i e heater hot water tank Hook Up Location 1 Water OUT to heater or hot water tank T Fitting required at temp sender location Location...

Page 70: ...y be inserted anywhere in the specified hose for most appropriate routing Location 1 Water OUT to heater or hot water tank Location 2 Water RETURN from heater or hot water tank FRESH WATER FLOW A A 1...

Page 71: ...in kit does not ensure that all of the water will drain out of the system Engine angle routing of drain hose and restricted drain fittings are some things that could prevent all of the water from drai...

Page 72: ...T 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 labele...

Page 73: ...d reassembly instructions Troubleshooting and maintenance charts are also included 2 PARTS Parts manuals with exploded views for service parts are available for all current engine models IMPORTANT Whe...

Page 74: ...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...

Page 75: ...days of the date of sale PCM OWNERSHIP CHANGE NOTICE If you are the new owner of a Pleasurecraft Marine Engine on which the warranty has expired and would like to inform Pleasurecraft of your ownersh...

Page 76: ...LOG Engine Port Drive Port Ignition Key Port Model and Serial Stbd Serial Stbd Number Stbd Fire Extinguisher Checked Batteries Tested Gal of Qts of Oil Oil Check Lay Up Launch Runs Made Date Fuel Por...

Page 77: ...is form to Pleasurecraft Marine PO Drawer 369 Little Mountain SC 29075 Engine Model Engine Serial Number Gear Serial Number Owner Information Name Telephone Address City State Zip Selling Dealer Deale...

Page 78: ...76 L510010 07A This Page Was Intentionally Left Blank...

Page 79: ...77 L510010 07A NOTES 19...

Page 80: ...Pleasurecraft Engine Group 1737 Highway 76 East Little Mountain SC 29075...

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PCM 2007 5.0L MPI, Owner'S Operation And Maintenance Manual

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