PCM 5.0 and 5.7L illustrated parts manual

C A T A U I N A T T M C C C A C C A A T A A T T A A A A A A A A A A A A A U U U I I I N N N A A A T T A A T T T T T T T T M M M T M s M M M s s M M M M M M M M M M M s s M M M s M M M M c c c M M M M M M M M M M M c M M M c M M CLEAN EMISSION SYSTEM L510013-08 01/08 MARINE ILLUSTRATED PARTS MANUAL MODELS MP/CES 5.0/5.7L MY 2008

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MODEL MP5.0/5.7L PARTS MANUAL - 1 PRO SPORT / EXCALIBUR L510013-08 Contents: Symbols ................................................................................................................................... 2 Maintenance Item Part Numbers ................................................................................................... 3 Cylinder Block Assembly - Figure 1 ................................................................................................ 4 Cylinder Head Assembly - Figure 2 ................................................................................................ 8 Intake Manifold Assembly - Figure 3 ............................................................................................. 10 Intake Manifold Components - Figure 4 ......................................................................................... 12 CES - Intake Manifold Components - Figure 5 ................................................................................ 14 Oil Pan and Oil Pump Assembly - Figure 6 ..................................................................................... 16 Throttle Body and Related Components - Figure7 .......................................................................... 18 Remote Oil Filter Components V-DRIVE - Figure 8 ......................................................................... 20 Remote Oil Filter Components DIRECT DRIVE - Figure 9 ................................................................ 22 CES - Remote Oil Filter Components - Figure 10 ............................................................................ 24 Fuel Control Cell (FCC) Components SN 473065 and Above - Figure 11 ............................................. 26 Heat Exchanger and Components - Figure 12 ................................................................................ 28 Fresh Water Cooling System Components - Figure 13 .................................................................... 30 Raw Water Cooling System Components - Figure 14 ...................................................................... 32 CES - Raw Water Cooling System Components - Figure 15 ............................................................. 34 Exhaust Manifold and Components - Figure 16 ............................................................................... 36 CES - Exhaust Manifold and Components - Figure 17 ...................................................................... 38 Raw Water Cooling Pump - Figure 18 .......................................................................................... 40 Wiring Harness Assemblies and Senders - Figure 19 ....................................................................... 42 ECM and Relays - Figure 20 ....................................................................................................... 44 CES - ECM and Relays - Figure 21 .............................................................................................. 46 Accessory Drive System Components - Figure 22 .......................................................................... 48 Starter Assembly Components - Figure 23 ..................................................................................... 50 Engine and Transmission Mounts - Figure 24 ................................................................................. 52 Bellhousing Assembly - Figure 25 ................................................................................................ 54 Transmission and Related Parts (1.23:1 FWC) - Figure 26 ................................................................ 56 Transmission and Related Parts (1.23:1 RWC) - Figure 27 ............................................................... 58 Transmission and Related Parts (1:1 V-Drive) - Figure 28 ................................................................ 60 Right-Hand Rotation Engine Components - Figure 29 ...................................................................... 62 “TYPICAL VIEWS ARE SHOWN” ENGINE ROTATION Engine Rotation is identified as “RH” or “LH” with the engine model number. Rotation always is determined from the flywheel end looking toward the front of the engine. In some instances, propeller shaft rotation may be opposite to that of the engine. When ordering a replacement engine, production block or parts for the engine, be certain to check engine rotation. DO NOT rely on propeller rotation in order to determine engine rotation. LEFT-HAND ROTATION is STANDARD ROTATION. (Flywheel turns counterclockwise when viewed from flywheel end of the engine.) RIGHT-HAND ROTATION is OPPOSITE ROTATION. (Flywheel turns clockwise when viewed from flywheel end of the engine.)

MODEL MP5.0/5.7L PARTS MANUAL - 2 L510013-08 PRO SPORT / EXCALIBUR Symbols shown throughout parts list are defined here or on the bottom of the individual parts list page. AR = As Required OPT = Optional NSS = Not Serviced Separately NA = Not Available OS = Oversize US = Undersize NS = Not Shown TBD = To Be Determined NI = Not Illustrated ===================================================================== ===================================================================== HOW TO READ THIS PARTS BOOK: 2 1 4 3 5 ITEM PART NO. QTY. DESCRIPTION MODEL ID 1 RB001005I 1 Base Engine Assembly, 5.7L ITEM NUMBER - This number corresponds with the number in the exploded view on the facing page. PART NUMBER - This is the designated part number for the particular component or assembly. QUANTITY - This refers to the number of pieces used. DESCRIPTION - This identifies what the component or assembly is. MODEL ID - This identifies a component or assembly that is unique to a specific engine model. 1 2 3 4 5

MODEL MP5.0/5.7L PARTS MANUAL - 3 PRO SPORT / EXCALIBUR L510013-08 REPLACEMENT PARTS: WARNING: Electrical, ignition and fuel system components on PCM Engines are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize risks of ﬁre or explosion. Use of replacement electrical, ignition and fuel system components which do not comply with these rules and regulations could result in a ﬁre or explosion hazard and should be avoided. MARINE TRANSMISSIONS: PCM Engines are equipped with PCM or Hurth Transmissions, standard or “V”-drives. If transmission parts are required, contact your dealer or closest PCM Parts Distributor for required parts. Parts manuals and overhaul manuals are available through PCM Distributors. MAINTENANCE ITEM PART NUMBERS: Description Part Number Oil Filter R077001 Kit, Transmission Oil Filter (ZF) RP077011 Fuel Filter, Primary R080024 Fuel Filter (FCC), Kit RP080026 Spark Plugs RP030010 Spark Plug Wire Set RK120018 Spark Plug Wire Set, CES RK120023 Serpentine Belt R066028 Impeller Kit (Serpentine Raw Water Pump) RP061022 Oil Drain Kit RK024179 Exhaust Service Kit, 5.0/5.7L, MP engines only RP173091

MODEL MP5.0/5.7L PARTS MANUAL - 4 L510013-08 PRO SPORT / EXCALIBUR CYLINDER BLOCK ASSEMBLY - FIGURE 1 59 58 56 57 55 54 47 48 43 49 50 51 60 42 53 52 7 8 46 1 2 3 4 5 6 9 10 11 12 13 20 19 18 17 16 15 14 23 22 21 13 24 25 26 27 28 29 39 40 41 28 45 44 30 37 38 36 35 34 32 31 DO NOT REMOVE PC57B01112-08 22 33 61 12A 12B

MODEL MP5.0/5.7L PARTS MANUAL - 5 PRO SPORT / EXCALIBUR L510013-08 ITEM PART NO. QTY. DESCRIPTION MODEL ID CYLINDER BLOCK ASSEMBLY - FIGURE 1 * RB001004B 5.0L Base Engine Assembly * RB001005I 5.7L Base Engine Assembly 1 R015013 8 Ring Set, piston 5.7L (STD) 1 R015006 8 Ring Set, piston 5.0L (STD) 2 RA013016 8 Piston, 5.7L (STD) 2 RA013017 8 Piston, 5.0L (STD) 3 TBD 16 Bolt, connecting rod cap 4 RA011012 8 Connecting Rod (STD) 5 R007023 8 Bearing Set, connecting rod (STD) 6 TBD 16 Nut, connecting rod cap 7 R035038 16 Lifter, valve 8 R037001 8 Guide, valve lifter 9 R069064 1 Plug, camshaft 10 TBD Plug, oil gallery 11 R079051 1 Adapter, oil bypass 12 R095043A 2 Adapter, flat response knock sensor xx-5xxXC-xx 12A R020052 2 Sensor, flat response knock (retaining bolt p/o sensor) xx-5xxXC-xx 12B R143156 2 Decal, “Raw Water Drain” xx-5xxXC-xx 13 TBD 1 Bearing, crankshaft rear main (STD) 13 TBD AR Bearing, crankshaft rear main (.001 US) 13 TBD AR Bearing, crankshaft rear main (.010 US) 13 TBD AR Bearing, crankshaft rear main (.020 US) 14 TBD 2 Pin, flywheel locating 15 TBD 1 Gasket, crankshaft rear oil seal housing 16 R134070 1 Housing, crankshaft rear oil seal 17 TBD 2 Bolt, crankshaft rear oil seal housing, short 17 TBD 1 Bolt, crankshaft rear oil seal housing, long 18 R047173A 1 Seal, crankshaft rear oil 19 RA138008 AR Flywheel Assembly (Top Mount Starter) 19 RA138010 1 Flywheel Assembly (Bottom Mount Starter) 20 TBD 6 Bolt, flywheel attaching 21 TBD 2 Nut, crankshaft rear oil seal housing 22 TBD 2 Stud, crankshaft rear oil seal housing 23 TBD 2 Stud, crankshaft rear oil seal housing 24 NSS 1 Cap, crankshaft bearing #5 25 TBD 5 Stud, crankshaft bearing cap 26 TBD 5 Bolt, crankshaft bearing cap 27 NSS 4 Cap, crankshaft bearing #1 - #4 28 TBD 4 Bearing, crankshaft main (STD) 28 TBD AR Bearing, crankshaft main (.002 US) 28 TBD AR Bearing, crankshaft main (.010 US) 28 TBD AR Bearing, crankshaft main (.020 US) 29 R056001 1 Ring, crankshaft position sensor reluctor

MODEL MP5.0/5.7L PARTS MANUAL - 6 L510013-08 PRO SPORT / EXCALIBUR CYLINDER BLOCK ASSEMBLY - FIGURE 1 (cont’d) 59 58 56 57 55 54 47 48 43 49 50 51 60 42 53 52 7 8 46 1 2 3 4 5 6 9 10 11 12 13 20 19 18 17 16 15 14 23 22 21 13 24 25 26 27 28 29 39 40 41 28 45 44 30 37 38 36 35 34 32 31 DO NOT REMOVE PC57B01112-08 22 33 61 12A 12B

MODEL MP5.0/5.7L PARTS MANUAL - 7 PRO SPORT / EXCALIBUR L510013-08 ITEM PART NO. QTY. DESCRIPTION MODEL ID CYLINDER BLOCK ASSEMBLY - FIGURE 1 (cont’d) 30 R004010A 1 Cover, engine front cover (includes gasket and seal) 31 R020038 1 Sensor, crankshaft position 32 TBD 1 Bolt, crankshaft position sensor attaching 33 RK007020 1 Bearing Set, crankshaft main (STD) 34 R009091 1 Bolt, crankshaft balancer 35 R096074 1 Washer, crankshaft balancer bolt 36 R064010A 1 Balancer, crankshaft - ‘02 and newer 36 R064010 1 Balancer, crankshaft - ‘97-’01 37 NSS 1 Seal, crankshaft front oil 38 R009177 6 Bolt, engine front cover attaching, short 38 R009176 2 Bolt, engine front cover attaching, long 39 NSS 1 Gasket, engine front cover 40 R054024 1 Sprocket, crankshaft 41 R164024 2 Key, crankshaft balancer 42 RK051030 1 Bearing Set, camshaft 42 TBD 1 Cam Bearing #1 42 TBD 2 Cam Bearing #2 & #5 42 TBD 2 Cam Bearing #3 & #4 43 R022022 1 Pin, camshaft sprocket locating 44 TBD 1 Bolt, camshaft sprocket attaching 45 R055011 1 Chain, camshaft timing 46 R054041 1 Sprocket, camshaft 47 TBD 2 Bolt, camshaft retaining 48 R109050 1 Retainer, camshaft 49 RA050021 1 Camshaft, engine 50 TBD 1 Plug, oil gallery 51 NSS Block, engine 52 R090253A 1 Retainer, valve lifter 53 RS0279 3 Bolt, valve lifter retainer 54 RM0203 2 Gasket, water pump to engine block 55 RA057027 1 Water Pump Assembly 56 R095026 1 Stud, water pump attaching 57 RS0307 1 Bolt, water pump attaching 58 90305275 1 Bolt, water pump attaching 59 R095026 1 Stud, water pump attaching 60 R020027 2 Sensor, knock 61 R006017A 1 Crankshaft, 350 1996/Later NI R069066 8 Plug, Brass, block 1 5/8”

MODEL MP5.0/5.7L PARTS MANUAL - 8 L510013-08 PRO SPORT / EXCALIBUR CYLINDER HEAD ASSEMBLY - FIGURE 2 24 23 20 19 17 16 15 14 30 29 28 27 26 25 13 9 10 8 18 21 22 19 20 20 20 20 20 20 20 20 18 CYLINDER HEAD BOLT POSITION 18 18 18 18 18 18 19 12 11 34 XXXX XXX XXX XXXXXX XXXXXXX 1 4 5 2 6 3 7 32 13 31 PC57B009_06 33 36 37 35 38

PCM 5.0 and 5.7L illustrated parts manual

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