Crusader Engines Product Installation Manual

E N G I N E S PRODUCT INSTALLATION MANUAL 03/07 L510023-07 Retail Price $12.00

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Welcome to the growing family of Crusader Marine Engines owners. We are delighted you have chosen Crusader power for your boat and wish you many years of enjoyment. When you chose Crusader, you selected the utmost in premium power for your boating application. Pleasurecraft is the world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting edge technology. 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. READ THIS MANUAL THOROUGHLY Before you begin the installation of your new Crusader engine, READ THIS MANUAL CAREFULLY AND COMPLETELY. There are many new and exciting features available with your new Crusader that you may wish to take advantage of and plan for as you begin the installation of your new Crusader engine. Crusader Sync-N-Cruz - Every new fuel injected Crusader engine is capable of twin engine synchronization and cruise control with the addition of the Crusader Sync-N-Cruz Kit RF152007. This kit includes a harness and control panel which provides for a very simple installation for plug and play operation. For twin engine applications, the Master/Slave engine harness is required. Crusader Engines has worked closely with FW Murphy who makes available 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 and / or instrument you are considering, prior to purchase, for compatibility with the Crusader ECM-07 system. Crusader Engines has taken care to develop a complete line of adapters and boat harnesses to make your new installation as seamless as possible. Items available include adapters for engine to existing boat harness, twin engine Master/Slave harness, engine alarm kit, electric fuel solenoid valves, and water separating fuel filters. Please read this manual carefully and plan ahead. There may be additional items that you may wish to replace or upgrade as you install your new Crusader engine. If you do not understand any portion of the manual or require additional supplies or accessories, contact your Distributor/Dealer for clarification or assistance. The descriptions and specifications contained in this manual were in effect at the time of printing. Crusader Marine Engines’ policy of continued improvement reserves the right to change specifications or design without notice and without obligation. This manual will cover the following Crusader engines: Year Model 2007 5.0L MPI 2007 5.7L MPI 2007 6.0L MPI 2007 8.1L MPI 2007 8.1L MPI (HO) 2007 Classic 5.7L Carburetor Part Number - L510023-07 Printed 03/07

1 L510023-07 TABLE OF CONTENTS SECTION...................................................................................................................……................................................ Page General Information ….....……...……...……..........................................……...……...……...………......... 3 Engine Models …..............…...…............…...……...……..............……...……...……...……...………...... 3 Crusader Accessories …..............…...……..................................……...……...……...……...………......... 3 Engine Installation Accessories …..................................................……...……...……...……...………......... 3 Installation Supplies …...................…...……...……................................……...……...……...………......... 3 Installation Drawings …...................…...…...……...…...................……...……...……...……...………........ 3 Engine and Transmission Combinations …..............….........……..……...……...……...……...………......... 4-6 Transmission Rotation …..............…...……...……...…................……...……...……...……...………....... 6-7 Gear Ratio Selection …..............….......……...……...……...............…...……...……...……...………......... 8 Propeller Shaft / Coupling …..............…...…....……...…..............……...……...……...……...………......... 8 Transmission and Propeller Rotation ….............…...……...........….……...……...……...….......………......... 8 Propeller Selection …..............…...…….........……...…...............…...……...……...……...………......... 8-11 Boat Construction …..............…...……..........……...…......................................…...……...………......... 12 Installation Requirements …...........…...……...……..........……...……...……...……...……...………......... 12 Instrumentation …..............…...…..........…...……...……............……...……...……...……...………........ 13 Twin Engine Synchronization and Speed Control (Optional) ...........................……...…….................……....... 13 Master/Slave Wiring Connection …................…...….....................……...……...……...……...………......... 14 Engine Warning Kit (Optional) …....................…..................................……...……...….......………....... 14-15 Electrical System Precautions …................…...…........................................……...……........................... 16 Engine Harness Electrical Connector Identiﬁcation …........................….................…...…...……...……........ 17 Crusader Classic 5.7L Carburetor - Electrical System Precautions …....................….............……...……......... 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 Supply and Return Connections …............................................................................……...……........ 27 Fuel Inlet Restriction …..............…...…....…...……........................……...……...……...……...……......... 28 Fuel Lines …..............…...……...……...……...…….........................................….......……...……......... 28 Fuel System Pressure Check …................................................…...……...……...……...……...……......... 28 Gasoline Requirements …..............................................................................................……...……........ 29 Gasoline Containing Alcohol …..............…...…..............................……...……...……...……..................... 29 Fuel Stabilizer Recommendations for Ethanol Blended Fuel …...................................……...……...……......... 29 Fuel Filter Recommendations for Ethanol Blended Fuel …..............…...……...……...……...……...……......... 30 Exhaust System …...............................…...……....................…...……...……...……...……...……......... 31 Exhaust Risers …..............….....................……................…...……...……...……...……...……......... 31-34 Throttle/Shift Remote Control and Cables …..............................….……...……...……...……...………......... 35 Seawater Pickup Connection …..............…...……....................…...……...……...……...……...……......... 35 Seacock Size Recommendation …..............…...…...........…............……...……...……...……...……......... 35 Sea Strainer Recommendation …..............…...…...........…..........…...…...……...……...……...……......... 35 Crankcase Oil Dipstick Relocation …..............…................................……...……...……...……...……....... 35 Engine Installation …............................…...……....................…...……...……...……...……...……......... 36

2 L510023-07 SECTION...................................................................................................................……................................................ Page Torque Speciﬁcations …........................…...……....................…...……...……...……...……...……......... 36 Preliminary Engine Alignment ….............…...…….....................…...……...……...……...……...……......... 36 Final Engine Alignment …......................…...…….....................…...................…...……...................... 37-39 Throttle/Shift Cables …..............…..............……...............…...……...……...……...……...………....... 39-43 Audio Alarm System …..............…..............…….....................…...……...……...……...……...……......... 43 Exhaust System Connection …....…..............…….........................……...……...……...……...………....... 44 Engine Harness Connection ….....................……..................…...……...……...……...……...………........ 44 Battery Connection …..............…..............……..........…............……...……...……...……...………......... 44 Master Engine Speciﬁcations ….......................……..............…...……...……...……...……...……........ 45-48 Delivery Preparation …..............…..............……......................…...……...……...……...……...……........ 49 Pre-Delivery Checklist …............…................……..................….......…...……...……...……...……......... 49 Pre-Delivery Procedure …............…........................................…...……...……...…..……...……......... 50-59 INSTALLATION DRAWINGS: EXHAUST SYSTEM INSTALLATION GUIDELINES ...................................................................................... 60 CAPTAIN’S CHOICE INSTALLATION DRAWINGS: 5.7L BOSCH / VELVET DRIVE 72 REDUCTION .......................................................................................... 61 5.7L BOSCH / 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 ANGLE .............................................................................. 71 350XL-HT WITH VELVET DRIVE 72 SERIES V-DRIVE ............................................................................... 72 350XL-HT WITH VELVET DRIVE 72 SERIES REDUCTION .......................................................................... 73 350XL-HT WITH VELVET DRIVE 5000 SERIES - 8° DOWN ANGLE ............................................................. 74 Crusader Engines Distributors ….......…........................................…...……...……................................... 75 Appendix A Captain’s Choice and Xli Installation Drawings …........……...……...……...……...……......... A1-A40 Appendix B XL Series Installation Drawings …......................…...……...……...……...……...…............. B1-B30

3 L510023-07 GENERAL INFORMATION Notice to Installer Throughout this manual, “Warnings” and “Cautions” (accompanied by the International Hazard Symbol) are used to alert the installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “common- sense” operation, are major accident prevention measures. WARNING Hazards or unsafe practices which could result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. IMPORTANT: Indicates information or instructions that are necessary for proper installation and/or operation. Experience gained over the past several years has shown that marine engines fitted with electronic fuel injection (EFI) require carefully integrated fuel delivery systems. More specifically, the fuel tank, fuel supply and return lines, fuel filters and all their associated valves and fittings must be considered an integral part of any fuel injection engine package. This may require changes in both fuel system components and/or layout to assure compatibility and 100% customer satisfaction with the latest EFI engines. Any new or re-power application involving the replacement of a non-EFI engine with an EFI engine may require a new or modified fuel delivery system, from the tank to the engine, for proper operation. This installation manual has been published by Crusader Engines to aid installers when installing the products described herein. It is assumed that these personnel are familiar with the installation procedures of similar products 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 hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses an installation procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the product’s safety will be endangered by the installation procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. ENGINE MODELS This manual gives installation guidelines for the following engine models. MP 5.0L / MP 5.7L MP 6.0L MP 8.1L STD MP 8.1L HO Carb. 5.7L CRUSADER ACCESSORIES Instrument panels, wiring harnesses, propeller shaft couplers, etc. are available for this product. Contact your Crusader Engines Distributor or Crusader Engines Sales Department for a listing of these options. A list of Distributors is provided at the end of this manual. ENGINE INSTALLATION ACCESSORIES Electric Fuel Solenoid Valve P/N 23532 Solenoid Valve Power Harness P/N 98452 Water Separating Fuel Filter Kit P/N RK080033 Check Engine Lamp / Alarm Kit P/N RK179008 Crusader Sync-N-Cruz Kit P/N RF152007 Master / Slave Wire Harness: P/N RA121072C Adapter - Engine to Boat Harness see page 20 Boat to Engine Harness see page 21 INSTALLATION SUPPLIES Marine Lubricant Liquid Neoprene Perfect Seal or equivalent Loctite PST Pipe Sealant or equivalent Mount Adjustment Tool - P/N 22165 INSTALLATION DRAWINGS Installation drawings are at the back of this manual. These and archive installation drawings, are also available at crusaderengines.com

4 L510023-07 ENGINE AND TRANSMISSION COMBINATIONS Engine Rotation: Engine rotation is indicated by the model number on the engine serial number plate. Engine rotation is described by ﬂywheel rotation viewing from the rear of the engine (transmission end) looking forward to the water pump end. Refer to the Crusader Model Identiﬁcation/Advisory information below. Figure 1 Flywheel Showing LH Rotation CRUSADER MODEL IDENTIFICATION / ADVISORY MODEL 23 - 6 0 0 V - 0 1 SERIAL 670000 *SERIAL NUMBER I.D.* 1 st DIGIT INDICATES DECADE ENGINE WAS MANUFACTURED ( 5 = 1990, 6 = 2000, 7 = 2010 ) 2 nd DIGIT INDICATES YEAR ENGINE WAS MANUFACTURED. 1 st - 2 nd Space: MANUFACTURING CODE 3 rd - 5 th 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) 573 = 5.7L (350 CID RH Carburetor) (GM) 500 = 5.0L (305 CID LH MPI) (GM) 501 = 5.0L (305 CID RH MPI) (GM) 502 = 5.0L (305 CID LH Carburetor) (GM) 503 = 5.0L (305 CID RH Carburetor) (GM) 6 th Space: DRIVE CONFIGURATION blank - Direct Drive V - V-Drive 7 th - 8 th Space: SPECIFICATION CODE

5 L510023-07 Figure 2 Engine Applications - Typical 8 Degree Down Angle Transmission Figure 3 Engine Applications - Typical V-Drive Transmission

6 L510023-07 TRANSMISSION ROTATION Velvet Drive In-Line and V-Drive Transmission gear ratio (in forward gear) is marked on the transmission identification plate. Transmission output shaft rotation is indicated on a decal on the transmission case. IMPORTANT: Use of proper rotation propeller, indicated by the 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 FLYWHEEL FOR FORWARD POPPET BALL F N R Figure 4 Engine Applications - Typical Remote V-Drive Transmission

Crusader Engines Product Installation Manual

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