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Crusader 5.0L/5.7L/6.0L/8.1 MPI 8.1L MPI(HO) user manual(2)

1. 33 Propeller Selector bute EVI s iets 34 ENGINE BREAK IN PERIOD 25 ME 35 20 HOUR ENGINE INSPECTION oio trino ERR Exp US nese mesures oo 36 FUEL REQUIREMENTS naa nasai 37 Gasoline Requirements veces sire tue ese Ee TERR EIL nia I REIP 37 Gasoline Containing ATGOTIOL 37 DIL REQUIRE I proe 38 MEME 38 Transmission and V Drive Oil 38 ENGINE MAINTENANCE tae xa yx ra vida IMP RR RF REM save tes chee RF READS KE REPRE RENE 39 68 Engine 39 Checking sees 39 40 41 Electrical System Circuit amp s RARE 42 42 POUND TITRE 42 Electrical System
2. 1 Figure 15 3 Fresh Water Cooling System 8 1L Typical gt Crusader E G I N E S L510001 05 82 WATER FLOW DIAGRAMS 15 WARM UP OPERATION NORMAL OPERATION n BYPASS D BYPASS HEAT J HEAT EXCHANGER EXCHANGER FROM FROM EXHAUST EXHAUST MANIFOLDS MANIFOLDS COOLANT FLOW OVER TEMPERATURE OPERATION V loa Ss F BYPASS CLOSED EXCHANGER 2 Vj A FROM EXHAUST MANIFOLDS Figure 15 4 Thermostat Housing Waterflow Diagrams and Fill Riser Waterflow 8 1L Fresh Water Cooled EN GItnes 81900105 INSTRUMENTATION WIRING DIAGRAMS 16 ENGINE WIRE HARNESS COLOR CHART HARNESS CIRCUIT CIRCUIT ENGINE HARNESS NUMBER NAME WIRE COLOR GROUND BLACK TACHOMETER GRAY WATER TEMPERATURE TAN ENGINE ALARM TAN BLACK IGNITION PURPLE WHITE BATTERY RED WHITE STARTER YELLOW RED OIL PRESSURE LT BLUE CHECK ENGINE LIGHT BROWN WHITE DATA LINE ORANGE BLACK SO MNAMAWNA NOTE ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY NOTE POWER FOR A FUSED ACCESSORY PANEL MAY TAKEN FROM THIS LOCATION LOAD CANNOT EXCEED 30 AMPS NOTE The lig
3. OWNER S OPERATION and MAINTENANCE MANUAL PLEASURECRAFT ENGINE GROUP Crusader 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 READ THIS MANUAL THOROUGHLY Before starting your engine s READ THIS MANUAL CAREFULLY AND COMPLETELY If you do not understand any portion of the manual contact your Dealer for clarification or assistance Ask your Dealer for a demonstration of actual starting and operating procedures 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 2005 5 0L MPI 2005 5 7L MPI 2005 6 0L MPI 2005 8 1L MPI 2005 8 1L MPI HO Part Number L510001 05 Printed 12 04 TABLE OF CONTENTS SERVICE AND WARRANTY crier PR DRAKE KP ARX RKDRRKENEKPSRRRR RRADRRKERSRPRRAXKERMRRAKEPRASARdRE 4 19 cuve 4 Replacement Pants ET Tt 4 CEPR 4 Crusader Marine Engines Commitment to YOU oan Re RRERARRRARRRARRRRRAKRARERARRRASKRSRAKRRKERARXRARARE 5 Owner Warranty Registration
4. bru sm oak equ bte nein riid 25 Power Reduction T 26 Higi Engine Coolant Tompe rane XS 26 Low Engine PSS TE 27 Grande TABLE OF CONTENTS High Transmission Fluid Temperature a pea SAN EAR UE E A5 27 OPERATING INSTRUCTIONS su IRR 28 32 Engine 2 RE 28 28 5 29 starting Engine Fuel Injected EhginBS eir ra 30 31 32 Freezing Temperature 32 Operation in High Debris ATGBS emo Rea rodd nra cp pa aua Odien sno 32 CONDITIONS AFFECTING OPERATION 2 lt REM PRAKRRRR 33 34 Trimand Weight 33 Boat MERERETUR
5. m 55 Accessory Dive BOM H RHm 56 58 Changing 59 EIOS 60 62 Engine Maintenance LOU nsec ani AM RUNE S AMA E A RENTE 63 5 64 65 Visual INSPEC UON eer 66 Engine Fluid Capacities T 66 Transmission Fluid 66 Filter Requirements 67 Parts KIS 67 69 ENGINE SPECIFICATIONS 70 72 OUT OF SEASON STORAGE 73 76 Engine S ID 8 73 INTENSE REA YU TTG RIZR RET TRES 74 Battery Storage 74 OQ tOf Season Emagine Warm UP waneuterercetadeiws 75 Recommissioning After Storage 75 76 TROUBLESHOOTING INEAN SEAT ONETAN RA dst 77 79 WATER FLOW DIAGRAMS ako ux pao Rai RAERRKEEIR QRA RE RRERRREXRKPRARXARRPRR FEE S
6. 55 peddinbe uos jsneux3 Jezzng Jo pue due senec 301 4 GEC 1922198 Jo pue A 0 2001 042 dH 005 01 AHL 38 LSNW 440553444 1904 LNVLYOdWI LOM LOM 09 6 LOM sd 09 265 LOM 09 76 LOM 154 29 26 005 T s qie2 uononpas sues d OL FA uononpey 0 8701 4 022 922 LOM 154 09 2 LOM Q9 sd 29 66 922 1079 due sues d 01 uononpey JeMog dwe 0 8701 4 022 sev LOM isd Z Y LOM 154 09 76 LOM 154 29 76 OH 178 uononpes due sues d 01 1 uononpes 01 4 022 982 982 15 11 8 uononpes sues d Ob F GES uononpey 01 4 022 oee SNOILVOIJIO3dS WAV IV ONINYVM YALSVIN 90 LOM LOM 154 29 26 WW 022 Ww SNOILVOIsIDAdS
7. NnS 15 Service 16 Dealer s Responsibilities 2 cece cece cece enone neat 17 Traristerable 18 Direct Sale By OWNET tee sat 18 19 BOATING RESPONSIBILITY SK 20 22 Garbon Monoxide EPEE ANNE ES AC HMM UE ADU ABUTERE 20 Safe Boating 21 Water WISdOM ESEAS NNNNA 21 Operation and Maintenance 11 1 2200 66 e eremi eren nn ene 21 UN FROG e I M 22 ENGINE IDENTIFICATION 23 24 Engine Identical aaa aem 23 Owner Identification and Registration Information uai aua rara n rr RR RR RRRKE ER KRYRKERRRKPRRKE REPE RR KE RU RXE RR 23 2005 Model AOVIBOLV uv e ERE P Ian E ER p RERUM RA 24 ELECTRONIC FUEL INJECTION INFORMATION 25 27 Electronic Fuel
8. Anew Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed in the factory registration file OUTSIDE THE U S AND CANADA CONTACT YOUR LOCAL CRUSADER DEALER OR WARRANTY SERVICES AT 586 977 0100 FOR MORE INFORMATION ON HOW TO APPLY TO THIS PROGRAM IMPORTANT PURCHASER NOTICE The checks listed below are designed to insure safety and satisfaction Premier Crusader Dealer Technicians have received step by step instruction in the performance of the Pre Delivery Inspection Therefore we require the following inspection be performed at your expense by a qualified technician prior to delivery By signature the technician certifies that he she has checked the installation and operation of the engine and finds it to be performing properly All terms in the Limited Warranty located in the Engine Owners Manual still apply ENGINE MODEL ENGINE SERIAL TRANS SERIAL ENGINE HOURS HULL SERIAL Pre Delivery Checklist STARBOARD Check for Bulletins Belt and Pulley Inspect for Damage Engine Oil Check Drain Plugs Confirm roper Installation Fuel Lines onfirm No Leaks Drive Lube Check Battery Rating Charge and Level All Oil Lines C A C Check onfirm No Leaks Control Adjustments Confirm Proper Operation Water Lines onfirm No Leaks Gauges Check for Electrical Wiring Check Proper Operation for Proper Installa
9. CAUTION Do not overfill engine crankcase with oil as excess oil will be splashed by reciprocating engine parts onto the cylinder walls in greater quantity than the rings can control The oil subsequently will be drawn into the combustion chamber and burned Continuous operation under these conditions can cause carbon to form on combustion chamber surfaces which will adversely affect engine performance and may lead to premature engine failure Splashing or agitation of oil also may cause it to become aerated which will affect the oil pressure and may result in internal engine damage from lack of lubrication 1 Stop the engine if running Allow approximately 5 minutes for the oil to drain back into the oil pan 2 Remove the dipstick wipe it clean and reinstall it fully into the dipstick tube 3 Remove the dipstick and observe the oil level The oil level must be between the FULL and ADD marks If the oil level is below the ADD mark add specified oil to bring the level up to but not over the FULL mark on the dipstick Figure 11 1 ENGINE MAINTENANCE 11 ENGINE OIL DIPSTICK OPERATING DIPSTICK RANGE FULL MARK ADD MARK Figure 11 1 Engine Oil Dipstick Typical WARNING The machinery space must be closed anytime the engine is running to prevent injury to you or others on board Never operate the engine while someone is in the machinery space either closed or
10. D pue O M 7 HS3HJ lt ium gt Crusader E G I E S Figure 15 1 Fresh Water Cooling System 5 0 5 7L Typical L510001 05 80 WATER FLOW DIAGRAMS 15 p RAW WATER FLOW gt FRESH WATER FLOW 5 Drain Locations Y 2 raw water pump 2 drain hoses completely IMPORTANT Accessory i e heater hot water tank Hook Up NOTE Location A is the location in order to hook up a hot water accessory Figure 15 2 Fresh Water Cooling System 6 0L Typical ENGINES 6190105 eM WATER FLOW DIAGRAMS 15 fy jo pue uleig 5 4 55 2 b d H31VM HS3HH lt MO1N31vM em sesoy pue SOSOH ye y JOY JO Z 1 pue 3uoJ4J 10 JO pue 04 JO 1 0 LNO 49 8M 1 1 yue
11. PRESS portion of the warning light cluster if equipped A warning buzzer will also sound if equipped Figure 4 3 OIL PRESS Light Illuminated E I E S High Transmission Fluid Temperature During operation if the transmission fluid temperature exceeds 235 F 113 C the engine enters Power Reduction mode and illuminates the TRANS TEMP portion of the warning light cluster if equipped A warning buzzer may also sound if equipped y Figure 4 4 TRANS TEMP Light Illuminated If a problem occurs in any of the aforementioned areas return the boat to your Crusader Marine Engines Dealer for service L510001 05 27 OPERATING INSTRUCTIONS 5 ENGINE ALARM SYSTEM OPTIONAL The Crusader engine electronic system is programmed to control the engine alarm system This system utilizes an audible alarm and or optional indicator lamps to warn the operator of possible engine problems and that the engine s have entered the Power Reduction mode as covered earlier in this manual The alarm has a self checking feature programmed into the system This feature will sound the alarm for two short pulses upon initial start up of the engine If the alarm sounds during operation immediately throttle back to idle speed Observe the indicator lamps to locate the problem circuit If the boat can be safely navigated with one engine on twin engine application
12. 11 ON BOARD PARTS KITS ON BOARD PARTS KIT 5 7L RETURNLESS FUEL SYSTEM 05 TO Present LH RK173089F 05 Cap Disrbutor VS 0 ion ON BOARD PARTS KIT 5 7L RETURNLESS FUEL SYSTEM 05 TO Present RH RK173089G 05 Primary Fuel Filter Element 150 Micron 1 77014 Filter Element Racor Fuel Water Separator 1 47047 SparkPlug Set Platnum 0 CSCS ON BOARD PARTS KIT 6 0L MPI Fuse 20 Amp 0 Relay 12V Fuel Pump Ignition Start 1 SparkPlug Set Platnum 1 Primary Fuel Filter Element 150 Micron 1 77014 Filter and O Ring Kit FCC 1 RP080026 Belt Serpentine 1 R066029A 3 Box On Board 1 22433 i 3 04 5 ENGINE MAINTENANCE 11 ON BOARD PARTS KITS ON BOARD PARTS KIT 6 0L MPI RETURNLESS FUEL SYSTEM 05 To Present RK173092A 05 Relay 12V Fuel Pump Ignition Start 1 ON BOARD PARTS KIT 8 1L Relay 12V Fuel Pump Ignition Start 1 22 ON BOARD PARTS KIT 8 1L Relay 12V Fuel Pump Ignition Start 1 Primary Fuel Filter Element 150 Micron 1 RP077014 Filter Element Racor Fuel Water Separator 1 47047 15100010569 ENGINE SPECIFICATIONS 12 021 YOO 089 aiqeisnipy JON 000 292 punog ZI 0 001 4 01 2 0 292 3 041 8 2 9 9 2 1 6 9 6 8
13. YALSVIN 90 uononpes sues L d 0L 4 GES uononpes due 2 6 0 4 022 922 LOM Z Y 154 29 9 922 106 uoIssiwsued 005 eJnssoJg uiojs S Jan 55 934 eJnssaoJg T3dON der LY Crus L510001 05 E 5 N N Gist ENGINE SPECIFICATIONS 12 5 0 5 7 Liter 5 7 Liter 6 0 8 1 Liter LH ROTATION RH ROTATION LH ROTATION FRONT FRONT FRONT Qo DISTRIBUTOR FLYWHEEL END OF ENGINE ALL V 8 MODELS FIRING ORDER FIRING ORDER FIRING ORDER 1 8 4 3 6 5 7 2 1 2 7 5 6 3 4 8 1 8 7 2 6 5 4 3 Figure 12 1 8 Firing Orders TUNE UP SPECIFICATIONS Model MP 5 0L 275 HP MP 8 1L STD 385 HP MP 5 7L 330 HP MP 6 0L 375 HP MP 8 1L HO 425 HP Spark Plug Type R030010 R030011 R030009 0 060 in 0 060 in 0 060 in apak Pug aap 1 52 mm 1 52 mm 1 52 mm ia Ignition Not Adjustable Not Adjustable Not Adjustable 1 8 4 3 6 5 7 2 1 8 7 2 6 5 4 3 1 8 7 2 6 5 4 3 LH Rotation LH Rotation LH Rotation 1 2 7 5 6 3 4 8 RH Rotation C
14. every 25 hours of operation or 30 days whichever occurs first 3 Requires more frequent inspection if used in extremely salty polluted or mineral laden waters L510001 05 65 ENGINE MAINTENANCE 11 VISUAL INSPECTION Touch up scratches nicks and corrosion damage to the exterior finish of the engine Spray paint may It is important for the owner operator to visually inspect be obtained from your local Crusader Marine Engines the complete engine assembly at regular intervals Most dealer often costly repairs can be avoided if potential problems are corrected before there is a failure Protect engine finish from corrosion by periodically spraying the engine exterior finish with a rust Inspect the complete engine assembly for obvious fuel preventative oil such as WD 40 oil water or exhaust leaks Check for loose damaged or missing parts Check all hose clamps for adequate tightness Check the electrical system for loose or dirty connections or damaged wiring ENGINE FLUID CAPACITIES Model 5 0L 5 7L MP 6 0L MP 8 1L Crankcase Oil Capacity W New Filter Aluminum Pan 6 Quarts 5 67 1 5 Quarts 4 75 L 7 Quarts 6 65 1 Stamped Steel Pan 4 Quarts 3 8 1 N A N A Fresh Water Cooling System Capacity 23 Quarts 21 85 L 23 Quarts 21 85 L 33 Quarts 31 35 L TRANSMISSION FLUID CAPACITIES Velvet Drive 1 1 Ratio 1 2 2 5 Quarts 2 37 L DEXRON III Velvet Drive 1 52 2 91 1 Ratio 12 3 5 Quarts 3
15. FORMS 18 CRUSADER WARRANTY TRANSFER APPLICATION PORT OR SINGLE ENGINE The remainder of the original Crusader limited warranty is transferable within thirty 30 days of date of sale by the original owner user to a subsequent purchaser for the remainder of the unused portion of the original warranty term provided the engine s operating hours do not exceed 300 The original date of sale or original in service date whichever comes first begins the warranty coverage period Direct Sale by Owner Dealer or First Operator The second purchaser be registered as the owner and retain the unused portion of the warranty term by sending the following Original owner s Warranty Registration Card Copy of Bill of Sale Sales Contract Operator Contract Completed Warranty Transfer Application Warranty transfer fee Transfer Fee The fee for transfer is 50 00 per engine The applicable transfer fee must be submitted via certified check within 30 days of date of sale along with the transfer application information to Crusader Marine Engines Marine Warranty Transfer 40580 Van Dyke Blvd Sterling Heights MI 48313 USA Anew Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed in the factory registration file OUTSIDE THE U S AND CANADA CONTACT YOUR LOCAL CRUSADER DEALER OR WARRANTY SERVICES AT 586 977 0100 FOR MORE INFORMATION ON HOW TO APPLY TO THIS
16. Warranty Registration Card is located at the back of this manual 5 Engine Operation and Cafe T 6 Maintenance Records T 6 Local Service 6 Service Away Fiom MOMS Dm 6 Replacement Parts Inquiries 66 0 0 00 emen 7 lt ETDa SE 7 Applicable Limited Warranty 5 ien RRR es 7 Crusader Marine Engines One Year Limited Warranty For Engines Sold and Used the United States and Canada ccc cececensstseesecatacecesessneneesanseaseseesie 8 Items Not Covered Under the Limited Warranty sxc cacascsososccscsscsnsncsbisnestseveneunsibbensstcesciaunstbisnsuncesstauss 10 Things You Should Know About The Warranty Saura 11 California Emission Control Warranty Statement i rene oaa nud ao Ee e eon Rt pa eux RP REESE 12 Crusader Inc Model Years 2003 2008 General Emissions Warranty Coverage 13 Marine Transmissions pU RIAM RR A MAPS KM AMPIA DM E MES MEM MP RU M ERE 15 aptam s Choice Series Engines in
17. as proof of purchase Failure of purchaser to return such card will require the owner to provide a copy of the original Bill of Sale sales contract for the Product to be serviced Warranty claims will not be accepted until adequate Proof of Purchase is presented by the purchaser and the date of purchase is substantiated Access to Product Reasonable access must be provided to the Product for warranty service The warranty does not cover the removal and or replacement of boat partitions and or other components which must be removed for necessary access to the Product SERVICE and WARRANTY 1 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Crusader Inc hereinafter Crusader are pleased to explain the emission control system warranty on your Model Years 2003 2008 inboard engine In California new inboard engines must be designed built and equipped to meet the State s stringent anti smog standards Crusader must warrant the emission control system on your inboard engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your inboard engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warra
18. cont d Fresh water cooled models Clean sea water section Fresh water cooled models Check coolant for boil freeze protection Fresh water cooled models Change coolant Zinc Anodes Heat exchanger and cooler check condition Engine Assembly Exterior Surfaces spray with rust preventative oil D Cooling System SALT WATER AREAS ONLY Flush sea water section Notes X Denotes service to be performed by the owner operator O Denotes service to be performed by an authorized Crusader Marine Engines dealer A Use SAE 30 engine oil B All Velvet Drive and Hurth transmissions Use Dexron automatic transmission fluid C All Velvet V Drive transmissions Use Dexron III automatic transmission fluid All Walters V Drive transmissions Use Exxon Spartan EP 68 or SAE 30 engine oil All Crusader V Drive transmissions Use SAE 80W 90 gear oil D Use WD 40 penetration oil or equivalent Grande E G I E S As required X At least once each year X Every five years Every 30 days X Fresh water areas Every 60 days X Salt water areas Every 30 days X After use each day X 1 In fresh water areas every 100 hours of operation or 120 days whichever occurs first In salt water areas every 50 hours of operation or 60 days whichever occurs first n fresh water areas every 50 hours of operation or 60 days whichever occurs first In salt water areas
19. natural gas oil propane coal or wood is burned Carbon monoxide is commonly found in the exhaust of internal combustion engines boat power plants generators etc In addition open flame devices like cooking ranges heaters and charcoal grills also produce carbon monoxide Carbon monoxide accumulation in and around boats is affected by vessel geometry overall vessel design closeness to other structures wind direction boat speed and many other variables In no way can this section cover all of the possible variables Do not rely on this section as the exclusive listing of measures to prevent the accumulation of carbon monoxide Consult your boat operators manual for detailed information on the inspection and or maintenance of the exhaust system for your particular application If an inspection reveals possible leaks DO NOT operate your engine s until it can be serviced by a qualified technician Proper and adequate air circulation around and throughout the boat is absolutely necessary to aid in the prevention of carbon monoxide build up If you have any questions or concerns regarding the operation of your boat and carbon monoxide hazards DO NOT operate your engines until you have contacted your boat manufacturer 20 1510001 To find out more about making boating safer including how you can prevent carbon monoxide poisoning on recreational boats contact National Marine Manufacturers Association 200 East Ran
20. ul 0900 0100504 021 YOO 069 eiqeisnfpy 1oN eiqeisnfpy JON punoJc HOA ZI 2 8 0 022 2 494 3 041 VN 6 9 2 1 8 Ul 0900 1100504 021 YOO 089 aiqeisnipy JON eigeisn py JON punog HOA ZL 8 VOL 4 022 2 2797 3 041 VN 7 6 9 8 1 Ul 0900 6000504 021 YOO 059 eiqejsnfpy punog ZI 2 8 01 07 9 494 3 041 VN 2 6 9 2 2 8 ul 0900 6000504 021 YOO 059 sooJDep eiqejsnfpy JON eiqejsnfpy JON aiqeysnipy JON 001 02 sdwy 001 04 001 02 001 02 001 02 sdwy 001 04 punog ZI 8701 07 9 494 3 041 8 9 6 2 Z 2 G 9 7 8 1 ul 0900 0100504 021 YOO 099 p cv INVO HOA ZL uoniuB Buey 2 3 2 8 01 4 022 9 292 4 021 8 9 6 2 7 8 9 v 8 L dey x1eds x1eds ut 0900 0100504 ed 69 54 OL Edy 2
21. Arrestor 5 7L Typical CLAMP NOT SHOWN FLAME ARRESTOR 7 1 Z f Be Fm THROTTLE BODY Figure 11 18 Flame Arrestor 8 1L Typical L510001 05 55 ENGINE MAINTENANCE 11 DRIVE BELT INSPECTION Inspect the drive belt for excessive wear shredding or missing sections Inspect the drive belt for contamination from excessive dirt oil coolant or other substances that may effect the drive belt operation If a problem is found replace the belt after inspecting the following items The engine water circulation pump and alternator pulleys for signs of misalignment The engine water circulation pump and alternator pulleys for signs of rust or other damage Bent pulleys or tight bearings in the engine water circulation pump and alternator 8 1L ACCESSORY DRIVE BELT The Crusader 8 1L engine uses a single serpentine belt to drive the engine water circulation pump sea water pump and the alternator Alternator Circulation Pump Crankshaft Pulley Figure 11 19 8 1L Accessory Drive Belt Configuration Figure 11 20 Belt Tensioner 8 1L DRIVE BELT REPLACEMENT 8 1L 8 1L SERPENTINE BELT R066024A 1 Note the routing of the belt before removing 2 Using a 15 mm box wrench or socket turn the belt tensioner to relieve the tension on the belt Slide the belt off of the pulleys Release the tensioner slowly to prevent the tensioner from snapping against its st
22. E SERVICE and WARRANTY 1 TRANSFERABLE WARRANTY The product limited warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty This will not apply to the products used for commercial applications DIRECT SALE BY OWNER The second owner can be registered as the new owner and may retain the unused portion of the limited warranty The forms and instructions necessary to transfer the unused portion of the Crusader One year Limited Warranty are provided in Forms section 18 of this manual The Captain s Choice Series Extended Buyer Protection Plan is administered by First Protection Corporation and the remainder of that warranty can be transferred by following the instructions provided with your Buyer Protection Policy Upon receipt of the transfer application a new Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file Crusader d8 y 51000105 SERVICE and WARRANTY 1 Grande eNGItnes 81900105 49 BOATING RESPONSIBILITIES 2 CARBON MONOXIDE HAZARD Carbon Monoxide CO is a colorless odorless and tasteless gas You cannot see it smell it or taste it Prolonged exposure to carbon monoxide can lead to unconsciousness brain damage or death Carbon monoxide is produced when anything that contains carbon such as gasoline
23. LITTLE MOUNTAIN SC 29075 Figure 3 1 Engine Identification Decal OWNER IDENTIFICATION AND REGISTRATION INFORMATION We suggest that you record the following information for quick reference when ordering parts or requesting service or warranty Figure 3 2 Engine Identification Tag Locations 8 1L PORT STARBOARD Umeeme Ignition Key Number Boat Model ENGINE IDENTIFICATION 3 CRUSADER 2005 MODEL IDENTIFICATION ADVISORY 1 Space MANUFACTURER C Crusader 27 Space FACTORY FRESHWATER CLOSED COOLING X Freshwater Cooled Space Omitted If Raw Water Cooled 3 Space ENGINE ROTATION L Rotation Left Hand from Rear R Rotation Right Hand from Rear 4 Space ENGINE TYPE 5 7L 350 CID HO GM 5 0L 305 CID GM Q 6 0L 364 CID GM 8 1L 496 CID STD GM Z 8 1L 496 CID HO GM 5 Space DRIVE MANUFACTURER W Borg Warner H Hurth T Walters V Velvet Drive cast iron units specify 71c or 72c 6 Space DRIVE FUNCTION APPLICATION R Reverse Reduction V Vee Drive Reversed Risers F Full Reversing 7 Space PROPELLER SHAFT ROTATION L Left Hand Rotation R Right Hand Rotation MODEL C XL XH F L 245 SERIAL 651254 8 9 10 Spaces DRIVE GEAR RATIO OR REDUCTION The drive gear ratio will appear in these spaces which identifies th
24. U S Coast Guard approved could cause a fire or and maintenance procedures plus common sense explosion hazard and should be avoided operation are major accident prevention measures Always request that genuine Crusader Marine Engines replacement parts be used in any repairs or maintenance being performed on your engine s SAFETY WARNINGS Signals serious damage failure or breakdown of equipment severe injury or high probability of death to the user if proper precautions are not taken This signal word is applied in extreme situations Indicates a potential hazard which could result in personal injury CAUTION Indicates a hazard which could result in damage to equipment IMPORTANT or MPORTANT Used to provide information to perform a procedure more easily WARRANTY NOTICE Indicates a possible warranty exclusion oos SERVICE and WARRANTY 1 OWNER S SERVICE AND WARRANTY INFORMATION CRUSADER MARINE ENGINES COMMITMENT TO YOU Crusader Marine Engines is committed to assuring your satisfaction with your new Crusader engine Your Dealer also wants you to be completely satisfied and invites you to return for all your servicing needs both during and after the warranty period OWNER WARRANTY REGISTRATION It is important that your selling dealer fill out the Warranty Registration Card completely and it to the factory immediately upon the purchase of the new produ
25. Wiring and P Ma EE RES 42 Battery 43 Fresh Water Cooling System Sacrificial Zinc Anode AV ER 44 Cree mime Coolant X 45 Flushing Cooling System Sea Water ius iei oa oa rn o pana saa 46 Testing Coolant For Alkalinity 47 Draining Fresh Water Cooling Systemi 47 Filling Fresh Water Cooling System 48 Cleaning Sea Water Section of Heat Exchanger Fresh Water Cooled Applications Only 49 Fuel System Description RR REE Rl KAY 50 Fuel Control Sy Stent En 50 Servicing the prr 51 FCC Service Instructions Screw On Canister uu se a kac 52 Grussder 7 N GNE S TABLE OF CONTENTS Service Instructions Clamp On Canister naNO EO ER EER ET EERS 53 m 54 Water Separating Fuel Fiter 55 Priming Fuel Sy Stent sssi 55 Flame
26. fuel leaks after installation element replacement or draining the bowl DO NOT remove the FCC bowl unless servicing the filter element otherwise contamination or bowl O ring swelling may result Grande ENGINE MAINTENANCE 11 FCC Service Instructions FCC Screw on Canister WARNING Extreme caution must be exercised when servicing FUEL ESSURE the fuel system The fuel system operates under high pressure Use caution when removing or replacing components as residual pressure may be present Draining the FCC Bowl ENGINE OFF 1 Disconnect the two wire electrical connector 2 Hold the 3 4 jam nut located at the bottom T FUEL of the FCC bowl with a wrench Remove the FILTER 7 16 plug and drain the bowl contents into an approved container CAUTION Both fuel and water will drain from the FCC bowl m FUEL BOWL 3 Apply pipe sealant suitable for use with gasoline to the threads of the 7 16 plug 4 Tighten the 7 16 plug while holding the 3 4 jam nut with a wrench RAN 5 Reconnect the two wire electrical connector Figure 11 14 Fuel Control Cell FCC Screw on 6 Cycle the ignition key several times to run the Canister Typical electric fuel pumps and fill the FCC bowl with 7 Using a pick made of soft material such as a fuel Inspect the drain plug area for leaks toothpick remove the old O ring
27. open Never open the machinery space unless the engine is shut off and the engines rotating parts are stationary Rotating machinery can cause injury and even death if an accident should occur Extreme care must be exercised if a problem exists that requires operation of the engine with the machinery space open IS RECOMMENDED THAT UNCOVERED ENGINE OPERATION BE ATTEMPTED BY TRAINED AND QUALIFIED SERVICE PERSONNEL ONLY 81900105 99 ENGINE MAINTENANCE 11 Transmission Fluid WARNING CAUTION Crusader Marine Engines uses marine transmissions supplied by several manufacturers The maintenance requirements can be different between 2 Operate the engine until the engine and the these manufacturers It is important that you refer transmission reach operating temperature to the operation and maintenance manual supplied by the transmission manufacturer before you attempt 3 Stop the engine and quickly check the fluid level to perform maintenance on your own If no to minimize the drain back from the oil cooler maintenance manual is available Crusader Marine Remove the dipstick by turning the T handle Engines recommends that you contact your dealer counterclockwise Observe the fluid level service department for any required maintenance or service instructions 4 The fluid level should be at the FULL or MAX mark If low add the specified fluid through the dipstick tube Repeat checking procedures
28. replacement of the part Crusader original equipment parts are identical in all material respects to that part as described in the engine manufacturer s application for certification The use of any replacement parts not supplied by Crusader may not meet this requirement and will be grounds for disallowing a claim made under this Warranty Crusader will not be liable under this Warranty to provide warranty coverage for product failures caused by parts other than Crusader original equipment parts If you have any questions regarding your warranty rights and responsibilities or the location of Crusader warranty stations you should contact Crusader at 1 586 977 0100 005 SERVICE and WARRANTY 1 MARINE TRANSMISSIONS Crusader Marine Engines are equipped with transmissions designed built and warranted by other manufacturers Although much of the transmission warranty is handled through Crusader Marine Engines there may be issues for which you the owner may want to contact the transmission manufacturer directly The transmission suppliers are listed below for your reference A tag is attached to each transmission showing the manufacturer transmission model and serial number Have this tag information available whenever contacting the manufacturer Velvet Drive Transmissions 1208 Old Norris Road P O Box 238 Liberty SC 29657 Phone 864 843 9234 www velvetdrive com ZF Marine Hurth Marine Tr
29. the direction required to raise or lower the engine After the adjustment is complete tighten the lag bolt IMPORTANT Both the front mount or rear mount adjusting sleeves must be turned equally to keep the engine level from side to side 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 1 0 in MAX 25 mm TRUNNION BOLT Figure 11 33 Engine Extension 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 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 specifications FASTENER TORQUE SPECIFICATIONS 50 68 Propeller Trunnion Bolts 45 61 62 015 4 ENGINE MAINTENANCE 11 ENGINE MAINTENANCE LOG Operating Maintenance Repair Hours 1510001 05 63 ENGINE MAINTENANCE 11 MAINTENANCE SCHEDULE After 1st Every 50 Every 100 Location and Service 25 Hrs of Hours of Hours of Once Operation Operation Operation Each Year Check coolant level Fresh water cooled models only Engine Assembly complete Check for obvious leaks wat
30. will not shorten nor extend the warranty period s stated in paragraphs one 1 thru five 5 above 7 The engine owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted part provided that such diagnostic work is performed at a Crusader warranty station 8 To insure prompt repair under this Warranty Crusader will maintain a supply of warranted parts sufficient to meet the expected demand for such parts Any replacement part may be used in the performance of any warranty maintenance or repairs and will be provided by Crusader without charge to the owner Crusader SERVICE and WARRANTY 1 9 10 11 12 Parts covered under this warranty are spark plugs spark advance retard system ignition coil and or control module ignition wires PCV valve oil filler cap intake valve s intake manifold exhaust manifold exhaust valve s hoses clamps fittings tubing sealing gaskets or devices mounting hardware pulleys belts and idlers temperature check and valves and switches and electronic controls Exclusions The repair or replacement of any warranted part otherwise eligible for coverage under this Warranty may be excluded from such warranty coverage if Crusader demonstrates that the engine and or part has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or
31. 0 days whichever occurs first TRANSMISSION AND V DRIVE OIL REQUIREMENTS Recommended 1 Classification and Viscosity Transmission and V Drive Dexron Automatic Transmissions and V Transmission Fluid ATF Drives All or equivalent Exxon Spartan EP 68 Walters V Drive or SAE 30 Engine Oil Dexron III Automatic Transmission Fluid ATF or equivalent Velvet Drive All Hurth Gear Transmissions NOTICE WALTERS V DRIVES ONLY low oil pressure warning light is mounted on Walters V Drives The warning light will stay illuminated until the boat gets underway and the engine speed increases to sufficient RPM for the pump to maintain pressure This normally occurs at approximately 1200 RPM Extended cruising at low RPM such as when trolling is not harmful to the V drive even though the warning light may remain illuminated 38 y L5100105 ENGINE MAINTENANCE Refer to the MAINTENANCE SCHEDULE for a complete listing of required maintenance and the frequency at which it should be performed Some procedures may be performed by the owner operator while others should be performed by an authorized Crusader Marine Engines Dealer Before performing any maintenance or repair procedure not covered in this manual it is strongly recommended that a Crusader Marine Engines repair manual be purchased and read thoroughly CHECKING FLUID LEVELS Engine Crankcase Oil
32. 01 05 9 SERVICE and WARRANTY 1 9 ITEMS NOT COVERED UNDER LIMITED WARRANTY This Limited Warranty is limited to defects in material and workmanship To avoid misunderstandings regarding warranty coverage the following describes some but not all of the more common types of service that are not covered by this Limited Warranty Normal service requirements arising during the warranty period such as fuel system or ignition adjustments tune ups filter adjusting controls or lubrications Damage caused by neglect lack of maintenance abnormal operation accident or improper installation or service Normal wear of the piston rings cylinders water pump and other engine parts Haul out launching towing charges dockage or storage fees removal and or replacement of boat partitions or material because of boat design for necessary access to the product All related transportation charges and or travel time The cost of shipping replacement parts by air freight or other premium freight methods Additional service work requested by the customer or performed by the dealer other than that necessary to satisfy the warranty obligation Labor performed by other than an authorized dealer may be covered only under the following circumstances when performed on an emergency basis providing there are no authorized dealers in the area who can perform the work required and prior factory approval has been given to have the work performed at thi
33. 31 L DEXRON III Velvet Drive V Drive exc 5000 All Ratios 1 2 4 5 Quarts 4 26 L DEXRON III Velvet Drive 5000 exc V Drive All Ratios 1 2 3 0 Quarts 2 37 L DEXRON III Velvet Drive 5000 V Drive All Ratios 1 2 4 5 5 0 Quarts 4 26 4 73 DEXRON III Hurth Exc V Drive All Ratios 1 2 4 0 Quarts 3 79 L DEXRON III Hurth V Drive All Ratios 1 2 4 5 5 0 Quarts 4 26 4 73 L DEXRON III Walters RV 36D V Drive 1 5 Quarts 1 42 L SAE 30 1 Capacities are dependent on installation angle ALWAYS use the dipstick to determine the exact quantity of oil required Add the correct amount of oil to fill to the FULL mark on the oil level dipstick 2 Check the transmission fluid level at operating temperature and immediately after shutdown of the engine Grussder 66 Ll51000105 ENGINE MAINTENANCE 11 FILTER REQUIREMENTS Description Part No Oil Filter remote mounted 22679 Primary Fuel Filter Element RP077014 Water Separator Fuel Filter Element 47047 Fuel Control Cell FCC Fuel Filter Element RP080026 ON BOARD PARTS KITS ON BOARD PARTS KIT 5 7L LH 2005 TO PRESENT FCC FUEL SYSTEM RK173089D 05 Distributor HVS 7 Relay 12V Fuel Pump Ignition Start 1 ON BOARD PARTS KIT 5 7L RH 2005 TO PRESENT FCC FUEL SYSTEM RK173089E 05 Distributor HVS Filter and O Ring Kit FCC 1 RP080026 Grande ENGINES 6190105 ENGINE MAINTENANCE
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35. 7777151000105 UCU NE S CONDITIONS AFFECTING OPERATION 6 TRIM AND WEIGHT DISTRIBUTION Trimming of the boat and positioning of the weight gear and passengers inside the boat has the following effects on handling Trimming the bow up or shifting weight to the stern rear Normally used for cruising running with a choppy wave condition following sea for running at full speed Will generally increase speed and engine RPM Will cause the bow to bounce in rough water In extreme may cause the boat to porpoise When coming off plane it increases the chances of following wave splashing into the stern of the boat Trimming the bow down or shifting the weight to the bow front Normally used for cruising running against a choppy wave condition acceleration onto plane and operating at slow planing speeds Will improve rough water ride and handling n extreme may cause the boat to bow steer veer back and forth with little control E I E S BOAT BOTTOM To ensure maximum engine performance fuel economy and boat speed the bottom of your boat must be kept clean and free of marine growth and barnacles Marine vegetation may accumulate when the boat is docked and should be removed before operation If the boat is docked for long periods of time the water inlets may become clogged with growth and will cause the engine to overheat In most areas it is advisable
36. ADDRESS CITY STATE ZIP CITY STATE ZIP hereby certify the Pre Delivery Checklist on engine Technician 5 Dealer amp Date Crusader 81900105 89 and have corrected any abnormality revealed by this inspection Seller s Signature amp Date Purchaser s Signature amp Date FORMS 18 CRUSADER WARRANTY TRANSFER APPLICATION STARBOARD ENGINE The remainder of the original Crusader limited warranty is transferable within thirty 30 days of date of sale by the original owner user to a subsequent purchaser for the remainder of the unused portion of the original warranty term provided the engine s operating hours do not exceed 300 The original date of sale or original in service date whichever comes first begins the warranty coverage period Direct Sale by Owner Dealer or First Operator The second purchaser be registered as the owner and retain the unused portion of the warranty term by sending the following Original owner s Warranty Registration Card Copy of Bill of Sale Sales Contract Operator Contract Completed Warranty Transfer Application Warranty transfer fee Transfer Fee The fee for transfer is 50 00 per engine The applicable transfer fee must be submitted via certified check within 30 days of date of sale along with the transfer application information to Crusader Marine Engines Marine Warranty Transfer 40580 Van Dyke Blvd Sterling Heights MI 48313 USA
37. AM Retard 43 47 degrees Not Adjustable Not Adjustable Firing Order Grussder 77 4 055 6 68 OUT OF SEASON STORAGE 13 ENGINE STORAGE IMPORTANT This service should be performed by an Authorized Crusader Dealer Refer to FLUSHING COOLING SYSTEM before proceeding 1 Fill the fuel tanks with gasoline that does not contain alcohol and add a sufficient amount of gasoline stabilizer such as STA BIL fuel stabilizer to prevent the formation of fuel gum and varnish Follow the instructions on the container IMPORTANT If the boat is to be placed into storage with fuel containing alcohol in the fuel tanks the engine fuel system must be run dry at idle RPM Fuel tanks should be drained completely and fuel conditioner such as STA BIL added to any fuel remaining in the tanks Operate the bilge blower and be sure no fuel vapors are present when treating the engine Be sure the engine compartment is well ventilated to prevent a potential fire hazard 2 Run the engine and allow it to reach normal operating temperature Shut down the engine and change the oil and oil filter See ENGINE MAINTENANCE 3 Flush the cooling system if operating in salt water or brackish water areas See ENGINE MAINTENANCE Operate the bilge blower and be sure no fuel vapors are present when treating the engine Be sure the engine compartment is well ventilated to prevent a potential fire haza
38. CAUTION A discharged battery can be damaged by freezing 744 4 5055 6 OUT OF SEASON STORAGE 13 OUT OF SEASON ENGINE WARM UP RECOMMISSIONING AFTER STORAGE If it is necessary to start your engine s during cold IMPORTANT This service should be performed by weather storage refer to the following procedure an Authorized Crusader Marine Engines Dealer 1 Refer to Recommissioning After Storage to When recommissioning the engine after storage the make certain all drain plugs hoses batteries and following items should be checked connections are secure 1 Assemble the raw water pump and reinstall 2 Start the engine s and idle until normal engine on the engine oil pressure is reached 2 Check all the cooling system hoses Be sure 3 Raise the engine RPM and hold at 1500 RPM they are properly connected and all the hose until NORMAL operating temperature is reached clamps are tight 4 Raise the engine RPM again and hold at 2500 AN AUTION RPM Allow the engine to run for approximately 5 minutes in order to heat up exhaust system When installing the battery make certain that you connect the POSITIVE BATTERY CABLE to the 5 Return the engine to idle speed and shut the POSITIVE BATTERY TERMINAL first and the engine OFF NEGATIVE BATTERY CABLE to the NEGATIVE ma BATTERY TERMINAL last If the battery cables 6 Referto
39. ECM is the decision center of the system The ECM constantly monitors information from various sensors on the engine and electronically processes the information in order to control ignition timing and fuel delivery for optimum performance and fuel economy The ECM incorporates ao an engine overspeed protection calibrated to a specific SS RPM to prevent engine damage from over revving The sensors that the ECM monitors are Engine Coolant Temperature ECT Sensor Throttle Position TP Sensor e Manifold Absolute Pressure MAP Sensor Knock Sensor KS System Crankshaft Positioning CKP Sensor Camshaft Positioning CMP Sensor ntake Air Temperature IAT Sensor If for any reason one or more of these sensors or associated wiring malfunctions the ECM s built in self diagnostic system sets a trouble code and turns on the Check Engine light if equipped to alert the operator of a malfunction Figure 4 1 Check Engine Light Illuminated ENGINES 6190105 5 ELECTRONIC FUEL INJECTION INFORMATION 4 POWER REDUCTION MODE The ECM monitors engine oil pressure engine coolant temperature and transmission oil temperature whenever the engine is running If any one of these inputs indicate an abnormal reading the system will go into Power Reduction mode followed by the illumination of an indicator lamp and or sounding of the warning buzzer if equipped This is a feature that will help pro
40. Engine Storage and Draining are reversed the electrical system will be damaged Instruction to make certain the engine is fully protected from freezing during the remaining AN storage period WARNING Do not use jumper cables and or a booster battery Following this procedure will reduce the possibility of to start the engine Do not recharge a weak battery condensation build up in the engine exhaust system due in the boat Remove the battery and recharge in a to cold weather start ups ventilated area away from fuel vapors sparks or open flame 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 terminal spray 4 Readjust alternator and water pump drive belt tension 5 Check engine alignment 6 Check engine and transmission oil levels 7 Check engine mount fasteners OUT OF SEASON STORAGE 13 RECOMMISSIONING AFTER STORAGE CAUTION Failure to remove the excess storage oil from the engine s cylinders can cause hydrostatic locking to occur and severe damage to the engine 8 Before starting the engine be sure there is not an excess amount of storage oil left in the cylinders Remove the spark plugs Disable the fuel pumps and ignition high voltage spark by removing the MEFI System Relay Using rags draped over the exhaust manifolds or some other suitable material or method c
41. OVE 10 volts while the engine is cranking or the engine management system will not function Grande E G I E S TROUBLESHOOTING 14 Engine performance complaints usually fall under one of the basic headings listed in the Troubleshooting Guide When a problem cannot be easily diagnosed consult a Crusader Marine Engines Servicing Dealer for assistance Possible Cause Problem with the engine management system Battery switch turned OFF if equipped Remote control not in Neutral position Blown the ignition fuse or open circuit breakers Loose and or dirty wiring connections Dead Battery Improper starting procedure No fuel empty fuel tank No fuel to the throttle body TBI or the injectors MPI Engine flooded Ignition system malfunction Contaminated fuel L510001 05 Corrective Action Contact Crusader Marine Engines Dealer Turn the battery switch ON Position the remote control exactly in Neutral Replace the fuse reset circuit breakers Check the battery cables and starter circuit wiring Clean and tighten all connections Repair or replace the damaged wiring Recharge test and replace as necessary Refer to STARTING ENGINE in the OPERATING INSTRUCTIONS section Check the fuel tank level fill tank s Open shut off valve s Plugged fuel filters Plugged or kinked fuel lines or plugged fuel tank vent Faulty fuel pump check electrical connection
42. PROGRAM IMPORTANT PURCHASER NOTICE The checks listed below are designed to insure safety and satisfaction Premier Crusader Dealer Technicians have received step by step instruction in the performance of the Pre Delivery Inspection Therefore we require the following inspection be performed at your expense by a qualified technician prior to delivery By signature the technician certifies that he she has checked the installation and operation of the engine and finds it to be performing properly All terms in the Limited Warranty located in the Engine Owners Manual still apply ENGINE MODEL ENGINE SERIAL TRANS SERIAL ENGINE HOURS HULL SERIAL Pre Delivery Checklist PORT or Single Check for Bulletins Belt and Pulley Inspect for Damage Engine Oil Check All Drain Plugs Confirm Proper Installation Drive Lube Check All Fuel Lines Confirm No Leaks Battery Rating Charge and Level All Oil Lines Check Confirm No Leaks Control Adjustments All Water Lines Confirm Proper Operation Confirm No Leaks Gauges Checkfor Electrical Wiring Check Proper Operation for Proper Installation Record Propeller Size Rotation and WOT WOT RPM Diameter Pitch Rotation Record Fuel Pressure WOT 1 Trouble Codes Checked Trouble Codes Cleared L Dealer Reviewed Warranty with Owner DATE OF SALE 2ND Owner 1 DATE OF SALE 1st Owner 1st Operator 1 New Owner Previous Owner NAME NAME ADDRESS
43. RMRRANXZR XRA RR PARPRRKE 80 83 INSTRUMENTATION WIRING DIAGRAM yo RE 0 4 22026 FE PRD ERE kr PR 84 LITERATURE HaT DP C 85 e m 87 91 CRUSADER OWNERSHIP CHANGE 87 CRUSADER WARRANTY TRANSFER APPLICATION PORT OR SINGLE ENGINE 89 CRUSADER WARRANTY TRANSFER APPLICATION STARBOARD ENGINE 91 qe O 93 Crusader SERVICE and WARRANTY 1 SAFETY INFORMATION REPLACEMENT PARTS Safety Warnings and additional information or instructions are used to alert the installer operator of possible safety hazards in performing certain service Electrical ignition and fuel system components are or maintenance procedures incorrectly or carelessly designed and manufactured to comply with U S DANGERS and WARNINGS are accompanied by the Coast Guard rules and regulations to minimize the international HAZARD symbol possibility of fire or explosion hazard These Safety Warnings alone cannot eliminate the Use of replacement parts i e automotive after market hazards that they signal Strict compliance with etc in the electrical ignition and fuel systems which are these warning instructions while performing service not
44. Replace the impeller Check the cooling system for leaks Refill the system See Warning before removing the fill cap Clean and flush the exchanger Install the proper coolant mixture 50 antifreeze 50 water Replace the thermostat Replace the temperature sender Test and replace as necessary Add specified oil Check the engine for leaks Remove the required amount of oil Determine the cause of overfilled condition improper filling etc Change the oil and filter Determine the cause of dilution insufficient engine temperature excessive idling etc Grussdes E N G I N E s Malfunction Transmission slipping erratic operation Engine misses runs rough and or backfires Poor engine or boat performance Grande G N 5 TROUBLESHOOTING 14 Possible Cause Low oil level Transmission overfilled causing oil aeration Transmission shift lever not fully engaged Contaminated fluid Ignition system malfunction Plugged fuel filters Faulty fuel pump Plugged or kinked fuel lines or fuel tank vent Anti siphon valve faulty Flame arrestor dirty Ignition malfunction Throttle not fully open Damaged or improper propeller Excessive water in the bilge Excessive growth on the boat bottom Boat overloaded Dirty flame arrestor Engine overheating 1510001 05 Corrective Action Add specified oil Check the transmission for leaks Drain required
45. SYSTEM WIRING AND CONNECTORS The electrical system wiring and connectors should be checked periodically for loose or dirty connections and damaged wiring If electrical components or wiring show signs of corrosion deterioration or damage consult a Crusader Marine Engines dealer to make necessary repairs Grande 42 0559 BATTERY WARNING Battery electrolyte is a corrosive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body IMMEDIATELY flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte WARNING Hydrogen gases that escape from the battery when charging are highly explosive Do not use jumper cables and a booster battery to start the engine Do not recharge a weak battery in the boat Remove the battery from the boat and recharge in a well ventilated area away from fuel vapors sparks and open flames Grande E G I E S ENGINE MAINTENANCE 11 Follow maintenance instructions and warnings as supplied by the battery manufacturer If this information is not available follow these guidelines for the proper battery care Do not operate the 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 W
46. The repair or replacement will be performed at no charge to the owner Any such part repaired or replaced under this Warranty will be warranted for the remainder of the two 2 year period 4 Any part covered under this Warranty that is scheduled only for regular inspection in the written instructions to be found within the Crusader Owners Operators Manual is warranted for the period of two 2 years If the part fails during the period of warranty coverage Crusader will repair or replace the defective part at any Crusader warranty station The repair or replacement will be performed at no charge to the owner Any such part repaired or replaced under this Warranty will be warranted for the remainder of the two 2 year period 5 Any part covered under this Warranty that is scheduled for replacement as required maintenance in the written instructions to be found within the Crusader Owners Operators Manual will be warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled replacement Crusader will repair or replace the defective part at any Crusader warranty station The repair or replacement will be performed at no charge to the owner Any such part repaired or replaced under this Warranty will be warranted for the remainder of the period prior to the first scheduled replacement date for the part 6 Replacement of any part under this Warranty with a Crusader supplied part
47. ader N 1 1510001 05 70 511000 e 22 4 ue 2 2 euiBu3 eueg 0002 5 Nidy 0021 Nidy onj ay Jo 1 WF Wd 0002 70002 Nidy 11 71 ENGINE SPECIFICATIONS 12 Jezzng Jo pue dwe senec OL gt uononpes eunssaJg 28 Isd o gt dwe TTN d uononpes eunssaJg Isd o gt dwe TTN d uononpes eunssaJg 28 ues 139 o gt dwe duie TTN d GFA uononpes eunssaJg 28 uec 39 o gt TTN d GFA 8 uononpes Je og eunssaeJg 24 uec 59 0 gt d oG Fd 8 YMS
48. ader Marine Engines assumes no responsibility for the costs related to the 25 hour inspection This is the owner s responsibility L510001 05 35 25 HOUR ENGINE INSPECTION 8 After the first 25 hours of operation it is recommended that the engine be given an inspection Your boat dealer or a Crusader servicing dealer should be contacted to perform the necessary checks and adjustments to ensure the proper engine performance The following maintenance should be performed Change the engine and filter Check and clean the primary fuel filter returnless design fuel system only e Check the engine alignment nspect the accessory drive belt s and check the tension Check all the fluid levels Cooling System Inspect all the hoses for leaks damage and deterioration Check all the hose clamps for adequate tightness Exhaust System Inspect the entire exhaust system for leaks damage and deterioration Check all the hose clamps for adequate tightness Battery Check the electrolyte level and specific gravity Inspect the case for damage Check the battery cables and connections Engine Assembly Check for loose missing or damaged parts Pay close attention to engine mounts starter and alternator mounting fasteners NOTICE Crusader Marine Engines assumes no Check the throttle and the shift cable adjustments responsibility for the costs related to the 25 hour and check for freedom of movement insp
49. amount of oil Adjust the shift linkage and remote control Check the shift cables for freedom of movement and binding Determine and correct the contamination source and change the fluid Contact Crusader Marine Engines Dealer Replace the fuel filters Have fuel pump replaced by a Crusader Marine Engines Dealer Repair or replace the fuel lines Remove obstruction Clean or replace as necessary Clean the flame arrestor Contact Crusader Marine Engines Dealer Check the remote control and throttle body linkage for freedom of movement and proper adjustment Repair or replace as necessary Pump the water out and investigate source of entry Clean the bottom and paint with an anti fouling paint Reduce and or redistribute the load Clean the flame arrestor Repair the cooling system See Engine Overheats 79 WATER FLOW DIAGRAMS 15 gt yey jo Woyog Bumi pue 1972M 10 Jo eou jan ssejuunjes gt 04 JOPUSS duiej ye 1 Joy Jo 0 LNO yue Jo pue juol4
50. anced additive treatment The use of supplemental additives which are added to the engine oil by the customer are unnecessary and may be harmful Crusader Marine Engines does not review approve or recommend such products Synthetic Oils Synthetic engine oils are not recommended for use in Crusader Marine Engines Synthetics may offer advantages in cold temperature pumpability and high temperature oxidation resistance However synthetic oils have not proven to provide operational or economic benefits over conventional petroleum based oils in Crusader Marine Engines Their use does not permit the extension of oil change intervals Engine Oil Requirements The following chart shows the recommended oil viscosity for various ambient temperature ranges Recommended 1 Classification amp Viscosity Prevailing Ambient Temperature Above 50 F SAE 15W 40 SM SAE 5W 30 SM Below 50 F IMPORTANT The use of oils which contain solid additives non detergent oils or low quality oils specifically are not recommended WARRANTY NOTICE Crusader Marine Engines reserves the right to refuse warranty on part s and or engine s damaged by using improper fuels and engine oils Oil Change Intervals Common Crankcase oil and oil filter change Recommended intervals Initial oil change 1st 60 days 25 hours of operation whichever occurs first Regular oil changes Every 50 hours of operation or 12
51. and could cause premature engine failure See NORMAL CRUISING SPEEDS in SPECIFICATIONS Problems caused by WOT operation are considered abuse and are not covered under the Crusader Warranty NOTICE These engines incorporate an RPM REV LIMIT in order to prevent the engine from over revving oos WARNING Use this procedure ONLY when conditions are such that it can be done in complete safety The break in period of your engine is the first 25 hours of operation Proper engine break in is essential to achieve maximum performance longevity and minimum oil consumption During the break in period the following operation guidelines must be adhered to e After the engine is thoroughly warmed the boat is underway open the throttle to wide open throttle until maximum RPM is reached DO NOT EXCEED MAXIMUM RPM RPM should cease climbing after 10 to 20 seconds CAUTION DO NOT operate at full throttle in neutral at any time or at sustained full throttle during the first 5 hours of operation Thereafter use sustained wide open throttle in the event of an emergency Reduce the throttle to 2800 3000 RPM and cruise at or below this speed for 1 2 hour Reduce the speed to idle Go to wide open throttle until maximum RPM is reached and operate for approximately 1 minute Reduce throttle to 2800 3000 RPM and operate for a few minutes Bringing the engine speed from idle to wid
52. ansmissions 3131 SW 42nd Street Ft Lauderdale FL 33312 Phone 954 581 4040 CAPTAIN S CHOICE SERIES EXTENDED BUYER PROTECTION PLAN United States and Canada ONLY Captain s Choice Series Engines include a buyer protection plan which provides coverage against unexpected mechanical and electrical breakdowns for an additional two 2 years after the expiration of the Crusader Limited Warranty See the program brochure or your dealer for details SERVICE and WARRANTY 1 RESOLVING A SERVICE PROBLEM Your satisfaction and faith in the product are of major importance to your dealer and to Crusader Marine Engines Any problems with service warranty or operation of your Crusader powered boat will be resolved by your dealer He should be your primary source of information on your boat Should there be a misunderstanding or if your problem has not been resolved to your satisfaction please follow these steps Step One Discuss Your Problem With One Of The Dealership Management Personnel Misunderstanding or complaints can be resolved quickly by the dealer Discuss your problem with the dealership s service manager If you are still unable to obtain satisfaction contact the dealership s owner Step Two If Your Complaint Has Not Been Resolved To Your Satisfaction Contact The Crusader Captain s Club Concierge When contacting the Club Concierge e Call the confidential toll free number you received with your Capta
53. anty to owner user CRUSADER SHALL NOT BE LIABLE FOR ANY LOSS OF TIME INCONVENIENCE COMMERCIAL LOSS OR DIRECT OR INDIRECT INCIDENTAL except as specifically provided herein OR CONSEQUENTIAL DAMAGES Some state do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you This Warranty gives you specific legal rights and you may also have other rights which vary from state to state Any owner user hereby waives for himself herself itself and his her its successors and assigns a any and all claims for punitive damages and b all claims of negligence or strict liability or both In no event will Crusader s liability exceed the purchase price of the Products which is actually paid to Crusader make claim under this Limited Warranty contact the selling dealer from which your Crusader powered boat was originally purchased or the nearest authorized Crusader servicing dealer It is recommended that your warranty service be performed by the dealer which sold the Product to you because of that dealer s personal interest in you as a customer Your Crusader powered Product must be delivered to the servicing dealer within the applicable warranty period Proof of purchase may be required by the Crusader dealer to substantiate any warranty claim Use your Crusader Owner Warranty Registration Card to establish proof of purchase EF S 15100
54. as required until the fluid level is at the FULL or MAX mark Do not attempt to remove the transmission dipstick while the engine is running Hot transmission fluid could be sprayed from the dipstick hole 1 Remove the dipstick by turning the T handle counterclockwise Observe the fluid level Replace the dipstick and tighten securely 5 Replace the dipstick and tighten securely VELVET DRIVE TRANSMISSION HURTH TRANSMISSION SHIFT LEVER SHIFT LEVER DIPSTICK FULL MARK Figure 11 2 Transmission Dipstick and Location Gruasder Tl5100 00 ENGINE MAINTENANCE 11 LUBRICATION Shift Cable Throttle Cable Lubricate pivot points and exposed cable Figure 11 5 with SAE 30W 30 engine oil Lubricate pivot points and exposed cable Figure 11 3 with SAE 30W 30 engine oil BALL JOINT LUBRICATION POINTS DY lj 17 LUBRICATION POINTS Figure 11 5 Typical Shift Cable Figure 11 3 Typical Throttle Cable Shift Lever All Velvet Drive Transmissions Lubricate the detent ball and holes in shift lever Figure 11 4 with white grease Lubriplate or equivalent DIPSTICK Figure 11 4 Transmission Shift Lever Velvet Drive 5000 EN Gtnes 61000405 41 ENGINE MAINTENANCE 11 ELECTRICAL SYSTEM CIRCUIT BREAKER Main Circuit Breaker Crusader engines are equipped with a circuit breaker which provides electr
55. ature gauge to ensure the engine is operating within the normal temperature range If the temperature is abnormally high stop the engine immediately and determine the cause OPERATING INSTRUCTIONS 5 STOPPING ENGINE When returning to the dock or whenever stopping the engine bring the throttle back to the idle position After the engine reaches idle speed turn the ignition key to the OFF position Before stopping the engine after extended high speed operation allow the engine to idle at 1200 RPM for 3 to 5 minutes to allow the engine to cool down before shutting off the ignition After stopping the engine complete the following 1 Turn the battery switch OFF if equipped 2 Close the fuel valve 3 Close the seacock 4 Flush the cooling system if in a salt water area FREEZING TEMPERATURE OPERATION If the possibility of freezing exists the cooling system must be protected after the engine is shut off to prevent freeze damage to the engine Refer to OUT OF SEASON STORAGE for draining instructions OPERATION IN HIGH DEBRIS AREAS If the boat is to be operated in high debris areas a sea strainer should be installed in the water inlet hose to prevent debris from entering the cooling system The strainer used must be of sufficient size to allow an adequate supply of water for cooling the engine A minimum of 30 gallons per minute 114 liters per minute flow rate is required a2 7777 7
56. ct It identifies the name and address of the original purchaser product model s and serial number s and the selling dealer s name and address The dealer is also certifying that you are the original purchaser of the product Upon receipt of the Warranty Registration Card at the factory you will be issued an Owner Warranty Registration Card The Owner Registration Card is your only valid registration identification and must be presented to the servicing dealer should warranty service be required If your Owner Registration Card is not received within 30 days from the date of purchase please contact your boat dealer or engine seller The product warranty is not effective until the Product is registered at the factory Mail registration information to Crusader Marine Engines P O Box 369 Little Mountain SC 29075 NOTE OWNERS WARRANTY REGISTRATION CARD IS LOCATED AT THE BACK OF THIS MANUAL NOTICE Registration lists must be maintained by the factory and dealer on marine products sold in the United States and some foreign countries should notification under FEDERAL BOAT SAFETY ACT be required It is our desire to have all products registered at the factory should it ever be necessary to contact you Make sure your Dealer Distributor fills out the registration card immediately and sends the card to the factory Crusader SERVICE and WARRANTY 1 ENGINE OPERATION AND CARE Considering the investment that y
57. curing the heat exchanger ej end plates Remove the end plates and gaskets RAW WATER 7 DRAIN PLUG 2 Clean the water passages in the heat exchanger GASKET by inserting a suitable size wire brush into each passage Use compressed air to blow out loose particles Figure 11 12 Heat Exchanger and End Plate Removal Typical 3 Clean the gasket surfaces on the end plates and the heat exchanger Apply PerfectSeal to both sides of the new gaskets Install the end plates and the new gaskets onto the heat exchanger Install the bolts and tighten securely 4 Start the engine and inspect for leaks EN Gtnes 8190105 ENGINE MAINTENANCE 11 FUEL SYSTEM DESCRIPTION WARNING Extreme caution must be exercised when servicing the fuel system and or replacing fuel filter Gasoline is extremely flammable and highly explosive under certain conditions Be sure the ignition key is off and do not smoke or allow open flame in the area while servicing Wipe up any spilled fuel immediately WARNING Extreme caution must be exercised when servicing the fuel system The fuel system operates under high pressure Use caution when removing or replacing components as residual pressure may be present WARNING Make sure that there are no fuel leaks before closing the engine hatch WARNING Visually inspect unit for fuel leaks before operating the engine If fuel leaks are present DO NOT operate the engine co
58. d or demonstration of the particular type installed on your boat CAUTION Never shift transmission into or out of gear unless throttle is at the idle position Shifting transmission above 1000 RPM can severely damage boat transmission and engine IGNITION CHECK IGNITION SWITCH ENGINE FUSES LIGHTS BILGE BLOWER SWITCH Figure 5 2 Typical Dash Layout yooo OPERATING INSTRUCTIONS 5 STARTING ENGINE FUEL INJECTED ENGINES WARNING Electrical ignition and fuel system components on Crusader Marine Engines are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize risks of fire IMPORTANT Do not start the engine without water being supplied to the sea water pick up pump or sea water pump impeller will be damaged and subsequent overheating damage to the engine may result IMPORTANT The following items should be checked before starting the engine and each time the boat is operated Fuel system for any signs of leakage Operation of remote controls and steering Engine and transmission oil levels Fuel tank levels Exhaust system for leaks and tightness of the clamps Battery connections and water level in battery cells Accessory drive belt Cooling system for leaks If equipped with fresh water cooling check coolant level in recovery bottle Check for signs of water leaks at the exhaust
59. dolph Drive Suite 5100 Chicago IL 60601 6528 www nmma org 312 946 6200 United States Coast Guard Office of Boating Safety CG Headquarters G OPB 3 2100 Second Street SW Washington DC 20593 www uscgboating org 202 267 0984 American Boat amp Yacht Council Inc 3069 Solomon s Island Road Edgewater MD 21037 1416 www abyc com 410 956 1050 Crusade G I N E 05 5 SAFE BOATING SUGGESTIONS The nation s waterways are becoming increasingly crowded in order to enjoy them safely the operator should acquaint himself herself with safe boating practices Boating safely and seamanship courses are offered by the following national and state organizations Power Squadrons Coast Guard Auxiliary e Cross State provincial or local agencies in charge of water safety enforcement Crusader Marine Engines highly recommends that all power boat operators attend one of these courses To help locate a course being offered near you contact Boat U S Foundation s toll free national boating safety hotline 1 800 336 BOAT and in Virginia 1 800 245 BOAT WATER WISDOM The following are suggestions for safe operation of your boat to ensure the safety of yourself and your passengers Know your boat s loading and operating limitations DO NOT OVERLOAD Make periodic checks of safety equipment onboard Donot consume alcoholic beverages or take illegal drugs when operating a boat Some state
60. e access to the Product must be provided for warranty service This Limited Warranty does not cover 1 telephone or telegram charges towing charges storage launch and haul out charges loss or damage to personal property loss of revenue loss of time travel lodging inconveniences or other CONSEQUENTIAL DAMAGES or 2 removal and or replacement of boat partitions or material because of boat design for necessary access to the Product Grande 8 L51000105 SERVICE and WARRANTY 1 7 NO OTHER WARRANTY GIVEN THE OBLIGATIONS SET FORTH IN THE PRECEDING PARAGRAPHS ARE CRUSADER S SOLE OBLIGATIONS AND OWNER USER S EXCLUSIVE REMEDY CRUSADER MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED except to the extent provided in the immediately following paragraph AND MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE However to the extent that any warranty may be implied by law the term of such implied warranty shall be limited to a period of time corresponding to the period of express warranty applicable to the particular Product and its use by the owner user as set forth herein commencing on the date of the first retail sale of the Product to the first registered owner or registered user Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you This is sole warranty provided respecting Crusader s Products and no other party may make a warr
61. e necessary to bend or lift the hoses to allow water to drain completely 4 Remove the raw water pump impeller See ENGINE MAINTENANCE 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 discarded and a new one installed at the end of the storage period NOTE Removal of the impeller during storage will prevent the impeller vanes from drying and taking a permanent set 5 After the water has completely drained coat the threads of drain plugs with PerfectSeal or equivalent and reinstall in the proper locations Reinstall the hoses and tighten all the clamps securely 6 Loosen the engine alternator and raw water pump drive belt After draining is completed perform the additional required maintenance as outlined in the MAINTENANCE SCHEDULE under ONCE EACH YEAR BATTERY STORAGE Follow the battery manufacturer s instructions for storage If not available use the following instructions e Remove the battery from the boat and clean removing dirt and grease from the top of the battery Fill the battery with distilled water to the manufacturer s specifications Store the battery in a cool dry place Do not store on a concrete surface Periodically every 30 to 45 days check the water level and recharge the battery to the manufacturer s specifications Do not fast charge
62. e open throttle will load the engine and assist in seating the piston rings This cycle should be repeated from time to time during the first 5 hours of operation but wide open throttle should not be sustained for more than 1 minute During the remaining 20 hours of break in period the engines can be run at cruise speeds that are approximately 75 80 of the wide open throttle RPM occasionally varying the cruise speed by 100 RPM During the early part of the break in period the correct propeller selection can be confirmed With a normal load aboard the engine s RPM should reach but not exceed the maximum RPM as listed in the specifications section During the break in all gauges should be watched carefully and the speed should be reduced if abnormal readings become evident Crusader E G I E S ENGINE BREAK IN PERIOD 7 CAUTION DO NOT attempt to break in any engine by prolong idling or running at the dock The engine oil level should be checked often and oil added when necessary It must be understood that every internal combustion engine will use a certain amount of oil during operation to act as a lubricating and cooling agent especially during the break in period Oil consumption should decrease and become stabilized after approximately 100 hours of operation At the end of your 25 hour break in period contact your dealer and have the recommended 25 hour inspection done NOTICE Crus
63. e production gear specs The example gear number shown is a 2 45 1 If the gear being identified does not have 3 digits a 0 will appear in 10 space Example 2 0 1 will appear as 200 1 5 1 will appear as 150 MODELS ENDING WITH 000000 IN PLACE OF DRIVE 1 0 ARE BOBTAIL ENGINES 11 Space IGNITION FUEL TYPE USED D DISTRIBUTOR Carb E THROTTLE BODY INJECTION M MULTI PORT FUEL INJECTION SERIAL NUMBER 1 0 1 DIGIT INDICATES DECADE ENGINE WAS MANUFACTURED 5 1990 6 2000 7 2010 2 DIGIT INDICATES YEAR ENGINE WAS MANUFACTURED Crusade 4411005 ELECTRONIC FUEL INJECTION INFORMATION 4 ELECTRONIC FUEL INJECTION SYSTEM In most cases when the Check Engine light is on the engine s will lose some performance and or efficiency The Crusader Marine Engines covered in this manual but remain running adequately Also the light may go are equipped with an Electronic Fuel Injection out or become intermittent but a trouble code will be system which allows precise control of fuel and spark logged for future diagnosis delivery The fuel system components of the EFI system are In any case the operator must obtain service by an The electric fuel pump authorized dealer to determine the exact cause of the The throttle body assembly malfunction The fuel injectors The fuel injection system is controlled by an Electronic Control Module ECM The
64. e s It is imperative to note the following about DEX COOL engine coolant TIS PINK IN COLOR TO DISTINGUISH IT FROM CONVENTIONAL COOLANT THE SERVICE CHANGE INTERVAL ON ENGINES BUILT WITH DEX COOL IS 5 YEARS TOMAINTAIN FULL CORROSION PROTECTION DURABILITY DEX COOL MUST NOT BE MIXED WITH CONVENTIONAL CONTAINING SILICATE ENGINE COOLANTS e DEX COOL IS AN ETHYLENE GLYCOL BASED PRODUCT THEREFORE BOIL AND FREEZE PROTECTION ARE MEASURED IN THE SAME FASHION AS CONVENTIONAL COOLANTS TO FULLY REALIZE ITS MANY ADVANTAGES DEX COOL MUST NEVER BE MIXED WITH CONVENTIONAL COOLANTS DEX COOL can become contaminated by inadvertently topping off with conventional coolant adding conventional coolant to the system or even if fill drain containers are shared between coolants If contamination occurs the cooling system must be immediately drained and flushed and refilled with DEX COOL No short term damage will occur however the service interval will be reduced from 5 years to 2 years The fresh water cooling side of the cooling system must be filled with a 50 50 mixture of DEX COOL or equivalent which meets GM6277M extended life antifreeze and water solution IMPORTANT More than 50 antifreeze solution can contribute to an overheating condition IMPORTANT If the engine is being placed in winter storage the fresh water cooling section must be filled with a correct type of coolant and water s
65. ection This is the owner s responsibility 36 L510001 05 Crusader E G I E S GASOLINE REQUIREMENTS WARRANTY NOTICE Damage caused to the engine through the use of improper gasoline low quality or gasoline with an octane rating below the minimum requirements listed below is considered misuse of the engine Such damage is not covered by the Crusader Marine Engines warranty The ignition timing set by the factory requires the use of a high quality lead free regular gasoline with the following octane specification Pump Octane Number R M 2 PUMP 87 MINIMUM OCTANE RATING R M 2 METHOD Figure 9 1 Fuel Requirements NOTICE Most Crusader Fuel Injected engines are calibrated to operate on 87 octane fuel and maximum performance is obtained when using this fuel Some applications may require a higher octane fuel These particular applications will be noted If a slight pinging is heard during acceleration and the proper octane fuel is being used it is considered normal If a constant heavy knock occurs the engine should be evaluated by a Crusader Marine Engines service technician E N G I N E 5 FUEL REQUIREMENTS 9 GASOLINE CONTAINING ALCOHOL Gasoline containing alcohol either ethanol ethyl alcohol or methanol methyl alcohol is not recommended for use in your engine Gasoline containing alcohol will attract and hold moisture and may cause the following e Hard starting and opera
66. elt off of the pulleys Release the tensioner slowly to prevent the tensioner from snapping against its stop and possibly causing damage to the tensioner 3 Slide the new belt onto the pulleys using the same routing as noted prior to removal 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 The raw water pump impeller should be serviced every 50 hours or once a year whichever occurs first See Maintenance Schedule Locations A Figure 11 23 are access holes in order to loosen the raw water pump housing attaching bolts The bolts are secured in the pump by O rings and will not fall out during removal U510001 05 CHANGING OILS WARNING IMPORTANT The Federal Water Pollution Control Act prohibits the discharge of oil or oily waste into or upon the navigable waters and continuous zone of the United States if such discharge causes a film or sheen upon or discoloration of the surface of the water or causes sludge or emulsion beneath the surface of the water Violators are subject to a penalty of 5 000 00 Refer to the MAINTENANCE SCHEDULE for oil change intervals The engine and transmission oils should be changed prior to placing the boat into storage The transmission oil change should be performed by an authorized deale
67. er oil fuel and exhaust Remote Control and Steering System Check for proper operation Cooling System Check condition and tightness of all hose clamps Cooling System Inspect Replace raw water pump impeller Drive Belt Inspect condition and check tension Exhaust System Check condition and tightness of all hose clamps xi X Engine Assembly complete Check for loose missing or damaged parts especially engine mounts starter and alternator mounting fasteners Change engine oil and filter Engine Alignment Check and adjust if necessary Ignition Timing Not Adjustable Battery Check electrolyte level and specific gravity Inspect case for damage Check cables and connections X Electrical System complete Check for loose or dirty connections and damaged wiring X Flame Arrestor and Crankcase Ventilation System Clean and inspect X X Crusader G4 18100105 ENGINE MAINTENANCE 11 MAINTENANCE SCHEDULE cont d After 1st 25 Hrs of Operation Location and Service Hoses all Inspect for cracks swelling weather checking or other signs of deterioration Every 50 Hours of Operation Every 100 Hours of Once Operation Each Year Shift and Throttle Cable Linkage Inspect and lubricate A Fuel Filters Service or replace Transmission and V Drive Change fluid B C and clean strainer if equipped Hurth Only MAINTENANCE SCHEDULE
68. er high the filter to the bracket pressure Use caution when removing or replacing 3 Using two wrenches secure the housing closest components as residual pressure may be present to the low pressure fuel pump and unscrew the outer retaining fitting Separate the housing Dependent upon application the primary fuel filter may be located at the front rear or either side of the engine 4 Remove the seal and filter on the low pressure electric fuel pump This filter filters 5 Install new filter and seal then screw housing the fuel before it reaches the fuel pump back together 6 Secure filter to bracket by tightening the hose clamp 7 Open fuel shut off valve 54 015 9 9 8 Prime the fuel system Refer to procedures in this section 9 Turn the key to START position and crank the engine until it starts or 30 seconds elapse 10 Repeat step 8 if the engine fails to start 11 After the engine starts check for leaks and repair as necessary Water Separating Fuel Filter Water Separator Fuel Filter Service KIT 47047 1 Close the fuel supply line shut off valve Start the engine and let it run until it stalls from lack of fuel 2 Turn ignition key OFF NOTICE A rag should be placed under the bowl to absorb any spilled fuel 3 Using a wrench on the nut fitting on the bottom of the bowl unscrew the bowl 4 Remove the old seal from the head unit and the fil
69. ering or leaving harbor areas You are responsible for wake damage to other vessels and or property Do Not Fool With Fuel 1 2 pint of gasoline 15 sticks of dynamite 1 During fueling moor boat properly remove all passengers 2 Keep all doors hatches and ports closed 3 Shut down all electronic gear extinguish galley fires pilot lights and smoking materials 4 Do not overload tanks 5 Keep filling nozzles in contact with the fill pipe to prevent sparks 6 Secure the fill cap tightly wipe away any spillage 7 Mentilate all components for a minimum of five minutes before starting engines 8 Keep fuel lines and bilges clean Grande 4 4005 ENGINE IDENTIFICATION 3 ENGINE IDENTIFICATION ENGINE SPARK Fuel Oct Reg MIN 87 AVG MODEL PLUG RPM Eng Oil Type Above 50 SAE 15W 40 SJ Sy When ordering service parts or obtaining information RO always give the engine model and the serial number M This information can be found on the following decal acoso nt Ting Spark Plug Gap 1 ENGINE SPECIFICATION DECAL ZF HURTH MARINE ARCO ITALY 5 LL O FIRING ORDER 3 TRANSMISSION IDENTIFICATION PLATE THIS ENGINE CONFORMS TO ALL APPLICABLE U S GOVERNMENT STANDARDS FOR MARINE ENGINES IN EFFECT AT DATE OF MANUFACTURE
70. es the starboard side of the channel when returning from sea 4 Lighted Buoy GREEN This buoy has a quick flashing green light It indicates the port side of the channel when returning special caution required Small Craft Gale Winds Storm Winds Hurricane Winds up to 38 54 MPH over 55 MPH Winds over 38 MPH 63 MPH Storm Warning Signals Pennants by day Lights by night from sea The quick flashing light indicates Boat Capacity Load only to manufacturer s specifications Distribute load evenly keep it low Passengers should only ride on the parts of the boat that are designed for that purpose e f 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 the harbor with red Or q buoys to your right Keep to Right Boat being overtaken Yield to boats in narrow has right of way approaching in channels Overtaking boat must this area stay clear Know Your Horn Signals 1 Short Blast Passing you on my port side 2 Short Blasts Passing you on my starboard side 3 Short Blasts am going astern 5 Short Blasts Danger Always refer to the latest U S Coast Guard Navigation Rules CG 169 Keep An Alert Lookout For Bad weather Swimmers Other boats Water skiers Fisherman Divers and or any other obstructions Keep Your Wake Under Control particularly upon ent
71. fferent geographic locations and water make up can result in either high or low sacrificial requirements A high rate of zinc anode consumption should also alert the owner to a possibility of an improperly wired boat accessory which would require complete checking by qualified service personnel Figure 11 7 Zinc Anode Location 8 1L F W C Heat Exchanger 4 151000106 ENGINE MAINTENANCE 11 CHECKING COOLANT LEVEL DEGAS BOTTLE WARNING Do not remove cooling system filler cap when the engine is hot Allow the engine to cool and then remove the pressure cap slowly allowing the pressure to vent Hot coolant under pressure may discharge violently and cause 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 overflow from the system Coolant level should be at or slightly above the ADD mark on the bottle when the system is cold Coolant should be added ONLY to the bottle when the system cools Figure 11 8 Checking Coolant Level 6 0L 8190105 ENGINE MAINTENANCE 11 FLUSHING COOLING SYSTEM SEA WATER SECTION To prevent silt and or salt build up in the cooling system fresh or raw water cooled flush the sea water section of the cooling system with fresh water at specified i
72. free number The Club Concierge is there to support your local dealer or locate the closest Crusader authorized technician She can personally expedite parts orders so that in most cases shipment is made within 24 hours delivered on time to the location you specify 751000105 SERVICE and WARRANTY 1 REPLACEMENT PART INQUIRIES All inquiries concerning replacement parts should be directed to your local authorized dealer The dealer has the necessary information to order parts for you if they are not in stock Only authorized distributors can purchase parts from the factory Crusader Marine Engines does not sell to unauthorized dealers or retail customers When checking on parts the dealer will require the engine model and serial number to order the correct parts REPLACEMENT SERVICE PARTS WARNING Electrical ignition and fuel system components on Crusader engines are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize the risks of fire or explosion Use of replacement electrical ignition or fuel system components which do not comply with these rules and regulations could result in a fire or explosion hazard and should be avoided When servicing the electrical ignition and fuel systems it is extremely important that all the components are properly installed and tightened If not any electrical or ignition component opening would permit sparks to ignite fuel vapors fr
73. from the inside Correct any leaks prior to operating the engine of the FCC bowl mounting head 7 Start the engine and inspect for fuel leaks CAUTION The mounting head O ring groove may Correct any leaks prior to operating the engine be damaged by using sharp steel tools to remove any further this O ring Filter Element Replacement ENGINE OFF 8 Lubricate the new O ring with a fuel resistant FCC SERVICE KIT RP080026 O ring lubricant and install the new O ring into the FCC bowl mounting head 1 Disconnect the two wire electrical connector 9 Apply pipe sealant suitable for use with gasoline 2 Hold the 3 4 jam nut located at the bottom to the threads of the 7 16 plug of the FCC bowl with a wrench Remove the 7 16 plug and drain the bowl contents into an approved container 11 Grease taper and the threads on the FCC bowl and by hand thread the FCC bowl into the FCC mounting head Tighten the bowl firmly back into 3 Using a strap type oil filter wrench remove the the mounting head with an oil filter wrench FCC bowl by turning it counterclockwise as viewed from the bottom 10 Install and tighten the 7 16 plug while holding the 3 4 jam nut with a wrench 12 Reconnect the two wire electrical connector 13 Cycle the ignition key several times to run the electric fuel pumps and fill the FCC bowl with fuel Inspect the drain plug area for leaks Correct any leaks prior to operating
74. g 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 before attempting to restart the engine 40 U510001 05 OPERATING INSTRUCTIONS 5 SHIFTING TRANSMISSION STARTING OR IDLE POSITION 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 damage the boat transmission and engine 1 Set the throttle lever at the idle position 2 Move the transmission lever completely forward to shift into Forward gear THROTTLE WOT 3 Move the transmission lever completely backward to shift into Reverse gear 4 Move the transmission lever to the center detent position to shift into Neutral Figure 5 3 Throttle Position Setting NEUTRAL NOTICE If engine still fails to start contact your Crusader Marine Engines Dealer for service 8 Check engine oil pressure immediately after the engine starts If oil pressure is not within specifications see Engine Specifications immediately stop the engine and determine the cause FORWARD GEAR 9 Check voltmeter for proper charging system operation 10 Check the engine and transmission for fuel oil water and exhaust leaks 11 Allow the engine to reach normal operating Figure 5 4 Shift Control temperature Check the temper
75. hen removing the battery cables always remove negative cable first and then remove the positive cable When installing battery cables install the positive cable first then install the negative cable Periodically check the battery for signs of corrosion frayed battery leads or cracked case Repair or replace as necessary Periodically check the electrolyte level Add distilled water to bring up to the proper levels IMPORTANT Your engine is designed to work with the standard electronics installed in your boat If you add other electrical components or accessories you could change the way the fuel injection controls your engine or the overall electrical system functions Before adding electrical equipment consult your dealer If you don t your engine may not perform properly CAUTION Add on equipment may adversely affect the alternator output or overload the electrical system Any damage caused as a result will not be covered by and may void your warranty L510001 05 43 ENGINE MAINTENANCE 11 FRESH WATER COOLING SYSTEM SACRIFICIAL ZINC ANODE HEAT EXCHANGER PROTECTIVE ANODE Located in the raw water side of the heat exchanger is a zinc anode which is marked by a decal To check remove the plug and visually check the condition of the zinc rod The length of the zinc rod when new is approximately 1 5 inches If more than one half of the zinc is gone replace with a new zinc anode Di
76. ht green wire pigtail located near the engine harness connector is for connection of a buzzer or light to indicate low oil pressure Figure 16 1 Typical Instrumentation Wiring IMPORTANT Your engine is designed to work with the standard electronics installed in your boat If you add other electrical components or accessories you could change the way the fuel injection controls your engine or the overall electrical system functions Before adding electrical equipment consult your dealer If you don t your engine may perform properly CAUTION Add on equipment may adversely affect the alternator output or overload the electrical system Any damage caused as a result will not be covered by and may void your warranty Crusader 51000105 To obtain service and or parts literature for your Crusader Marine Engine contact the following Crusader Marine Engines Pleasurecraft Engine Group Publications Department 1737 Highway 76 East Little Mountain SC 29075 IMPORTANT When contacting the factory for service information be sure to include your engine model and serial number to insure the service information you receive is correct 1 s L51 0001 05 LITERATURE 17 85 FORMS 18 SUMMARY OF WARRANTY TERM LIMITS This list does not in any way modify the official Limited Warranty Statement of Crusader Engines This list has been compiled o
77. ical overload protection for both engine and instrumentation wiring and components Should an electrical overload occur the circuit breaker will open and prevent electrical current flow When this circuit breaker opens the cause for the high current draw must be found and corrected The circuit breaker can be reset by pushing the Reset button IN after waiting a few minutes If the cause of the overload cannot be found disconnect all accessories which are connected to the main wire harness If resetting is still not possible check the battery and alternator connections and all other harness connectors on the main harness Check for loose or disconnected lead wires and shorted circuits ELECTRICAL SYSTEM FUSES Crusader engines utilize fuses to control the fuel pump ECM and fuel injectors The fuse block is mounted to a bracket near the exhaust elbow under a weather tight cover FUSE BLOCK CIRCUIT BREAKER Figure 11 6 Typical Electrical System Circuit Breaker and Fuses IGNITION FUSE If the engine will not crank when the ignition key is turned to the START position first check that the shift lever is in neutral position If the main circuit breaker is not tripped check for blown ignition fuse The ignition fuse may be located on the instrument panel the fuse holder block or as part of the instrument wiring harness Check the wiring diagrams supplied from the boat manufacturer for the exact location ELECTRICAL
78. in s Club membership between 8 00 a m and 5 00 p m EST Monday through Friday e Have your Captain s Club membership card availabe so you can provide the Club Concierge with your PIN Details of your problem or complaint Your Crusader engine warranty Captain s Choice Series Extended Buyer Protection Plan and Captain s Club membership are activated when your dealer sends in the warranty registration cards for your engine s You will recieve your Crusader Captain s Club membership package after Crusader receives the warranty registration card s If you have not received your Club membership follow up with your dealer to ensure that your engine s warranty registration has been filed Crusader d6 5000 5 SERVICE and WARRANTY 1 DEALERS RESPONSIBILITIES In general the dealer s responsibilities to you the customer include pre delivery inspection and preparation such as Make sure that the boat is properly equipped Prior to delivery make certain that the Crusader Engine is in proper operating condition Make all necessary adjustments for maximum efficiency Familiarize you the owner with the on board equipment Explain and demonstrate the operation of the engine and also the boat Explain warranty policies and deliver all operating manuals for the engine and the boat Complete the owner s warranty registration card and return it to the factory N E S L510001 05 17
79. ized Crusader service center Crusader in its discretion may provide for the repair or replacement of any defective part at Crusader s facility Crusader will make payment for labor to replace such parts as provided in the then current flat rate labor manual or Warranty Procedures Manual 3 This Limited Warranty does not apply to Product defects caused by normal wear and tear to Products and or damage to Products arising out of negligence or lack of proper care improper installation or service operation with fuels oils or lubricants which are not suitable for use with Products alterations or removal of parts water entering an engine through the exhaust system or carburetor installation of accessories or parts not manufactured or sold by Crusader or Products rendered defective by accident 4 part should become defective within the applicable warranty period advance authorization by Crusader 15 necessary before the part is replaced or a defect is corrected by a service representative otherwise Crusader will not be liable for the expense of the replacement or correction 5 Replacement parts and accessories supplied by Crusader and installed on a Product during the period when the Product is covered under the provisions of this Limited Warranty are warranted for the unexpired portion of the existing warranty period or ninety 90 days from the date of installation of such new parts or accessories whichever is longer 6 Reasonabl
80. laws apply to boats as well as motor vehicles File a float plan Let someone know your destination and your expected time of return Monitor the weather Know the signs of weather change and avoid severe weather and rough 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 boat is equipped with the required safety equipment Check with the Coast Guard and local government agencies as to the regulations and restrictions in your area Contact your local Coast Guard Auxiliary and take advantage of their seasonal boat inspections Crusader BOATING RESPONSIBILITIES 2 The following is a list of suggested safety equipment and spare parts which may be useful in case of an emergency Approved personal flotation devices life jackets one for each person on board Approved throwable personal flotation device for man overboard protection Approved fire extinguishers Signal devices flares spotlight signal flag and horn or whistle Crusader Marine Engines Onboard Kit plus spare fuses bulbs batteries etc Tools necessary for minor repairs Spare propeller Anchor and anchor line First aid kit and first aid book Ship to shore radio compass and chart of the area in which you are traveling Manual bilge pump and spare drain plugs Wate
81. manifolds risers and elbows Figure 5 2A If the water is leaking externally it is possible that the water is also leaking internally This could result in internal engine damage It is very important to service these maintenance items as soon as a problem is indicated Check for signs of external leaks Check for signs of external leaks Figure 5 2A Water Leaks After performing the initial safety checks proceed as follows to start the engine 1 Turn the battery switch ON if equipped 2 Open the fuel valve 3 Open the seacock 4 Place the remote control in Neutral position The transmission is equipped with a neutral safety switch which will not allow the starter motor to operate unless the transmission is in neutral 5 Do not pump or open the throttle when starting the engine Figure 5 3 The ECM will automatically regulate the fuel and control desired idle speed 6 Turn the ignition key to the start position When the engine starts release the key NOTICE Engine idle speed is controlled by the ECM and is based on the operating temperature of the engine Upon initial start up engine RPM will be slightly higher and will automatically decrease as the engine operating temperature increases 7 In the event the engine becomes flooded move the throttle lever to a 10096 open position Figure 5 3 Atthis throttle position the ECM will command the injectors to deliver no fuel during engine crankin
82. nly as a general outline of year and hour limits imposed on different models of Crusader engines Please review the official Limited Warranty Statements for specific terms and limitations as they apply to the particular engine component involved ENGINE MODEL YEAR WARRANTY COVERAGE TERM 2003 1 year unlimited hours GM engine 1 year unlimited hours Transmission 2004 1 year unlimited hours GM engine 1 year unlimited hours Transmission 2005 1 year unlimited hours GM engine 1 year unlimited hours Transmission Base Engine 1 year 200 hours with exclusions Note 1994 1998 1 year unlimited hours for Champion Series Platinum Series has addditional 4 years extended warranty administered by First Protection Corporation Captains Choice Series has additional 2 years extended warranty administered by First Protection Corporation CRUSADER OWNERSHIP CHANGE NOTICE If you are the new owner of a Crusader Marine Engine on which the warranty has expired and would like to inform Crusader of your ownership for notification purposes in case of Service Updates Recalls etc complete the section below and return by mail to Crusader Marine Engines PO Drawer 369 Little Mountain SC 29075 STARBOARD ENGINE SERIAL NUMBER TRANS SERIAL NUMBER HULL SERIAL New Owner NAME ADDRESS CITY STATE ZIP DATE OF PURCHASE Previous Owner NAME ADDRESS CITY STATE ZIP Grande ENGINES 6190105
83. nt O ring lubricant Apply pipe sealant suitable for use with gasoline to the threads of the 7 16 plug Install and tighten the 7 16 plug into the cansister Install the canister firmly back onto the FCC head Reinstall the retaining clamp and tighten securely Reconnect the two wire electrical connector Cycle the ignition key several times to run the electric fuel pumps and fill the FCC bowl with fuel Inspect the drain plug area for leaks Correct any leaks prior to operating the engine Start the engine and inspect for fuel leaks Correct any leaks prior to operating the engine any further 8 Using a pick made of soft material such as a DO NOT ATTEMPT TO SERVICE ANY OTHER PARTS toothpick remove the old O rings from the FCC ON THIS UNIT head Crusader ENGINES L510001 05 53 ENGINE MAINTENANCE 11 ELECTRIC FUEL PUMP C J AS Je 47 PRIMARY LOW PRESSURE FUEL FUEL PUMP FILTER WATER CANISTER SEPARATING FUEL FILTER Figure 11 16 Returnless Type Fuel System Typical Primary Fuel Filter 1 Close the fuel supply line shut off valve Start Primary Fuel Filter Service KIT RP077014 and let it run until it stalls from lack of 2 Turn ignition key OFF WARNING NOTICE A rag should be placed under the filter to Extreme caution must be exercised when servicing absorb any spilled fuel Loosen the hose clamp securing the fuel system The fuel system operates und
84. ntable condition exists Crusader will repair your inboard engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Select emission control parts from Model Years 2003 2008 inboard engines are warranted for 2 years OWNER S WARRANTY RESPONSIBILITIES As the inboard engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Crusader recommends that you retain all receipts covering maintenance on your inboard engine but Crusader cannot deny warranty coverage solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the inboard engine owner you should however be aware that Crusader may deny you warranty coverage if your inboard engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your inboard engine to a Crusader distribution center as soon as a problem exists The warranty repairs will be completed in a reasonable amount of time not to exceed thirty 30 days If you have any questions regarding your warranty rights and responsibilities you should contact Crusader at 1 586 977 0100 Grussder 42 L51001056 S SERVICE and WARRANTY 1 CRUSADER INC MODEL YEARS 2003 2008 GENERAL EMISSIONS WARRANTY COVERAGE 1 Crusader Inc hereinafter referred to as Crusader warrants to the fir
85. ntact your service center immediately Crusader Marine Engines will be equipped with one of two fuel systems the Fuel Control Cell FCC or the Returnless Type The fuel system is best described as having a fuel feed line coming from the fuel tank and fuel line that returns unused fuel back to the fuel tank The Returnless Type fuel system requires a fuel feed line to supply fuel Unused fuel is circulated through a cooler and is eventually returned to the fuel feed line Fuel Control Cell FCC Fuel System The Fuel Control Cell FCC eliminates vapor lock and air ingestion caused by fuel tank slosh and provides the necessary filtration and water separation The FCC system incorporates two 2 fuel pumps to provide an uninterrupted flow of fuel to your Crusader marine engine Fuel is fed into the FCC bowl by a low pressure high volume electric fuel pump This pump flows fuel at a volume much greater than the fuel flow rate required of the high pressure pump and engine demands The high pressure pump mounted inside the FCC bowl provides the necessary fuel pressure and volume to maintain proper engine performance The FCC constantly has an ample supply of fuel to meet the idle cruise and acceleration fuel requirements of the engine The fuel pressure regulator located on the fuel rail controls the fuel pressure and maintains a constant pressure across the fuel delivery system 6 0L engines f
86. ntervals CAUTION Do not operate the engine without water being supplied to the sea water pump The sea water pump impeller may be damaged and subsequent overheating damage may result ATTACH FLUSHING ADAPTER REMOVING INLET HOSE CAUTION Do not run the engine above 1500 RPM when flushing Suction created by the sea water pump may collapse the flushing hose causing the engine to overheat Watch the temperature gauge while flushing to ensure the engine does not overheat Figure 11 9 Typical Sea Water Inlet 46 U510001 05 TESTING COOLANT FOR ALKALINITY It is recommended that the coolant in the fresh water section be tested each year for alkalinity Coolant that is not alkaline has lost the effectiveness of its rust inhibitors which can lead to internal corrosion and cooling system problems It is recommended to replace the extended life engine coolant known as DEX COOL in the system every five years to prevent a build up of harmful chemicals within the fresh water system 1 Obtain red litmus paper from a local supplier drugstore laboratory etc 2 Remove the pressure cap from the coolant filler neck and insert one end of the litmus paper into the coolant 3 If red litmus paper turns blue coolant is alkaline and does not need to be replaced If the litmus paper remains red the coolant is not alkaline and must be replaced Remove large HOSE or DRAIN PLUG if equi
87. olution properly mixed to protect the engine to the lowest temperature to which it will be exposed 1 Make sure that all drain plugs are properly installed 2 Remove the pressure cap from the Degas Bottle 3 Fill the system with antifreeze solution until the system is filled See ENGINE FLUID CAPACITIES for system capacities 48 1510001 05 4 Start the engine and operate at idle speed 800 1000 RPM to purge any air from the system Add additional coolant into the Degas Bottle to the MAX level When the coolant level remains constant in the Degas Bottle install the pressure cap Continue to run the engine until it reaches normal operating temperature Check the Degas Bottle for the proper level and add coolant if necessary after the engine cools ANTIFREEZE Figure 11 11 Filling F W C System 6 0L Typical E N G I N E 5 ENGINE MAINTENANCE 11 CLEANING SEA WATER SECTION OF HEAT EXCHANGER FRESH WATER COOLED HEAT MODELS ONLY EXCHANGER The sea water section of the heat exchanger should THERMOSTAT be cleaned whenever there is a noticeable decrease in 7 HOUSING cooling efficiency You may use the following procedure for cleaning or if the build up of scale and mineral deposits is heavy it is recommended that the heat exchanger be removed and taken to a repair facility to be boiled out such as a radiator repair facility COOLANT r j DRAIN PLUG 1 Remove the bolts se
88. om fuel system leaks if they existed APPLICABLE LIMITED WARRANTY Following is the limited warranty applicable to Crusader Marine Engines sold and used in the United States and Canada Distributors and Dealers are not agents of Crusader Crusader does not authorize any person to create any other obligation or liability in connection with this product SERVICE and WARRANTY 1 CRUSADER INC INBOARD MARINE ENGINES ONE YEAR LIMITED WARRANTY For Engines Sold and Used in the United States and Canada Only 1 Crusader Inc hereinafter referred to as Crusader warrants each of its new inboard marine engines and accessories attached thereto Products to be free from defects in material and workmanship for a period of one 1 year except to the extent limited herein This Limited Warranty commences on the day of the first retail sale and or the first date used and extends to the original and subsequent retail sales however in no event shall the duration of the Limited Warranty exceed one 1 year as measured from the original retail sale date 2 Under this Limited Warranty Crusader s obligation is limited to repairing or replacing those parts of Products that have become defective within the applicable warranty period because of defective materials or workmanship Crusader will arrange for the correction of all defects under this Limited Warranty to be made free of charge at the selling dealership or an author
89. op and possibly causing damage to the tensioner 3 Slide the new belt onto the pulleys using the same routing as noted prior to removal 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 8 1L 8 1L IMPELLER KIT RP061022 The raw water pump impeller should be serviced every 50 hours or once a year whichever occurs first See Maintenance Schedule Locations A Figure 11 19 are access holes in order to loosen the raw water pump housing attaching bolts The bolts are secured in the pump by O rings and will not fall out during removal Grussder l51000105 6 0L ACCESSORY DRIVE BELT The Crusader 6 0L engine uses a single serpentine belt to drive the engine water circulation pump sea water pump and the alternator DRIVE BELT REPLACEMENT 6 0L 6 0L SERPENTINE BELT 066027 1 Note the routing of the belt before removing 2 Using a 15 mm box wrench or socket turn the belt tensioner to relieve the tension on the belt Slide the belt off of the pulleys Release the tensioner slowly to prevent the tensioner from snapping against its stop and possibly causing damage to the tensioner 3 Slide the new belt onto the pulleys using the same routing as noted prior to removal 4 Compress the belt tensioner and slide the belt over the tensioner pulley Release the tension
90. or 5 minutes to circulate the oil throughout the engine Check entire system for leaks especially around the oil filter 6 Stop the engine and wait 5 minutes to allow the oil to completely drain down Check the oil level and add oil if needed to bring the engine oil to the proper level 59 ENGINE MAINTENANCE 11 ENGINE ALIGNMENT CAUTION Engine must be properly aligned or vibration noise and damage to the transmission output shaft oil seal and bearings may result IMPORTANT Engine alignment MUST BE RECHECKED with the boat in the water fuel tanks full and with a normal load on the boat Engine must be aligned so that the transmission and the propeller shaft coupling center lines are aligned and coupling faces are parallel within 0 003 in 0 07 mm This applies to installations with solid couplings as well as flexible couplings 1 Check the mating surfaces on the transmission and the propeller shaft couplings Make sure they are clean and flat Figure 11 28 Shaft Mating Surface Check V Drives 2 Center the propeller shaft in the shaft log as follows e Push down then lift the propeller shaft as far as it will move then place the shaft in the middle of the movement Move the shaft to the port and then to the starboard as far as the shaft will move then place the shaft in the middle of the movement e With the propeller shaft in the middle of the
91. ou have made in your new Crusader engine s we know you will want to operate and maintain it properly We urge you to follow the maintenance instructions contained in your engine s Operation and Maintenance Manual If you have any questions on how to keep your engine in good working condition see your selling dealer the place where many owners choose to have their maintenance work done Your dealer can be relied on to use proper parts and practices MAINTENANCE RECORDS It is recommended that receipts covering the performance of regular maintenance be retained Damage to your engine caused by lack of maintenance is not covered under your warranty Receipts can be very important if a question arises as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship An Engine Maintenance Log is provided in the MAINTENANCE SCHEDULE section of the OPERATION AND MAINTENANCE MANUAL for your convenience in recording the service performed LOCAL REPAIR SERVICE To obtain service or make a claim under your warranty contact your selling dealer They have trained technicians knowledge and special tools and equipment to properly service your engine if the need arises They know you and your boat the best SERVICE AWAY FROM HOME If you are away from home and your local dealer and the need for service arises contact the Crusader Captain s Club Concierge using your exclusive Captain s Club toll
92. ponents Always replace with new fuel filter and gasket L510001 05 73 OUT OF SEASON STORAGE 13 DRAINING INSTRUCTIONS CAUTION If the boat is to remain in the water during or after draining close the seacock to prevent a siphoning action that may occur allowing sea water to flow from drain holes or removed hoses IMPORTANT When removing the drain plugs insert wire into the hole to remove any obstruction which would prevent water from draining completely FRESH WATER COOLED MODELS IMPORTANT The fresh water section of the cooling system must be kept filled year around with recommended coolant Make certain that the cooling system is protected with an ethylene glycol antifreeze mixture properly mixed to protect the engine to the lowest temperature that it will be exposed to See the ENGINE MAINTENANCE section for testing alkalinity draining and refilling procedures of the Fresh Water Cooling System as required IMPORTANT Drain the sea water section of the cooling system only 1 Remove all the drain plugs from the following locations e Heat Exchanger one on outboard side Exhaust Elbows 5 0 5 7 8 1L ONLY two on each side Transmission and Engine Cooler one drain plug Fuel Cooler Canister Returnless Fuel System Only one 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 b
93. pped Figure 11 10 Draining Engine Circulating Pump 5 0 5 7L Crusader E G I N E S ENGINE MAINTENANCE 11 DRAINING FRESH WATER COOLING SYSTEM NOTICE To protect the environment dispose of coolant properly Check your local restrictions for proper disposal instructions of removed coolant NOTICE Refer to cooling system water flow diagrams for drain locations 1 Remove the following drain plugs to drain coolant from the fresh water cooling system Drain plug on heat exchanger The hose and or drain plugs from the fitting on the bottom of the exhaust manifolds one on each side Drain plugs from risers Drain plugs on the cylinder block one each side Remove the large hose from the engine block water circulating pump or drain plug on circulation pump See Figure 11 10 2 Remove the following drain plugs to drain raw water from the fresh water cooling system plug on oil cooler Drain plug on heat exchanger Drain plug on fuel cooler canister returnless fuel system only 3 After system has drained completely coat all the drain plugs with PerfectSeal or equivalent and reinstall in the proper locations Reinstall the hose s on the water circulating pump and the exhaust manifolds and tighten the clamps securely L510001 05 47 ENGINE MAINTENANCE 11 FILLING FRESH WATER COOLING SYSTEM A new extended life engine coolant known as DEX COOL is used in your engin
94. precluded by other law of mandatory application SPECIAL STATE LEGAL REQUIREMENTS This Warranty gives you specific legal rights and you may also have other rights which vary from State to State The Crusader California Model Years 2003 2008 Emissions Warranty and California Emission Control Warranty Statement is a separate document included in this Manual Any questions concerning the Emissions Warranty can be obtained by calling 1 586 977 0100 1510001 05 E NE S SERVICE and WARRANTY 1 THINGS YOU SHOULD KNOW ABOUT THE WARRANTY Warranty Repair Component Exchanges In the interest of customer satisfaction Crusader Marine Engines may offer an exchange service on some engine components This service is intended to reduce the amount of time that your boat is not available for use due to repairs Components used for the exchange service may be new remanufactured reconditioned or repaired depending upon the component involved All exchange components used meet Crusader standards and are warranted the same as new components Production Changes Crusader Marine Engines and its Distributors reserve the right to make changes in the engines built and or sold by it at any time without incurring any obligation to make the same or similar changes on engines previously built and or sold Proof of Date of Purchase Crusader will accept the return of a properly filled out Warranty Registration Card supplied with each engine
95. r at specified intervals IMPORTANT Change the engine oil when the engine is warm from operation Warm oil flows more freely and allows more foreign material and impurities to be removed The engine oil filter is remote mounted The engine block location where the filter is normally mounted is covered with an oil filter bypass adapter DO NOT remove this adapter when changing the oil 1 With the engine at normal operating temperature remove the dipstick and install a crankcase oil pump onto the dipstick tube Figure 11 25 Insert the discharge hose into a suitable container Pump the oil from the engine until the crankcase is empty Remove the oil pump from the dipstick tube 2 Remove the oil filter by turning it counterclockwise using an oil filter wrench if necessary Discard the old filter and sealing ring Crusader E G I N E S L510001 05 ENGINE MAINTENANCE 11 OIL PUMP 4 DIPSTICK w JO EE NGS 3 AG S 2 E 10 PISE A 9 ZZ US CONTAINER Figure 11 25 Engine Oil Removal 3 Coat the sealing ring on the new filter with a light coating of clean engine oil Install the oil filter securely by hand DO NOT overtighten 4 Fill the engine with the recommended oil see OIL REQUIREMENTS through the oil fill location on the valve cover Figure 11 26 E rel D Figure 11 26 Engine Oil Fill 8 1L 5 Start the engine and operate f
96. rd 4 Restart the engine and allow it to idle for 5 minutes Grande E G I E S 5 Turn off the ignition and remove the spark plugs Use an aerosol type fogging solution and spray a sufficient amount into each cylinder Spray 5 seconds per cylinder minimum Turn the crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders NOTE If you are using a bulk type preservative oil pour approximately one 1 teaspoon full of oil into each cylinder through the spark plug hole then turn the crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders 6 Install the spark plugs and connect the spark plug wires NOTE It will be necessary to remove the spark plugs and spin the engine to eliminate excess oil prior to restarting after the storage period 7 Remove and clean the flame arrestor and the vent hoses and reinstall on the engine Cover the throttle body assembly to prevent the possibility of the water entering the engine through the throttle body assembly during storage 8 Close the fuel shut off valve if equipped WARNING On fuel injected engines you MUST bleed off fuel pressure before proceeding Failure to do so may cause personal injury 9 Remove empty and clean the fuel filter shell Reinstall with a new fuel filter and gasket Refer to Engine Maintenance for filter replacemnt procedures NOTE DO NOT re use old fuel filter com
97. reate a deflector or catcher for the oil that will be sprayed from the spark plug holes Turn the ignition switch to the start position and rotate the engine three 3 or four 4 times 9 Reinstall the MEFI System Relay 10 Install the spark plugs and connect the spark plug wires 11 Open the fuel shut off valve if equipped 12 Refer to the OPERATING INSTRUCTIONS section and perform all the safety checks before starting the engine 13 Refer to the Engine Maintenance section and perform the Priming the Fuel System instructions CAUTION If the engine s is are to be started prior to launching use the procedure FLUSHING COOLING SYSTEM before proceeding to start the engine s 14 Open the seacock before starting the engine 15 Start the engine and closely observe the instrument panel Allow the engine to reach normal operating temperature Inspect the engine carefully for fuel exhaust oil and water leaks 16 Check the steering shift and throttle controls for proper operation Crusade 76 015 4 Malfunction Check Engine light on with the engine running Engine will not crank with the starter motor or cranks slowly NOTICE Battery voltage must be AT or ABOVE 10 volts while the engine is cranking or the engine management system will not function Engine Cranks will not start or is hard starting NOTICE Battery voltage must be AT or AB
98. rproof storage containers OPERATION AND MAINTENANCE It is the owner s operator s responsibility to perform all safety checks before operating his her boat All lubrication and maintenance schedules must be adhered to assure optimum performance and dependability from your Crusader engine When service and maintenance are required return to your authorized Crusader Marine Engines Dealer BOATING RESPONSIBILITIES 2 RULES OF THE ROAD Channel Buoy Guide The color of the paint is the only characteristic which has the same meaning on all buoys Red buoys always indicate the starboard side of the channel from seaward Red Right Returning 1 Nun Buoy This buoy indicates the starboard side of the channel when A returning from sea It is conical shape the color red and indicates even numbers A nun buoy with red and green horizontal 7 bands top band and not numbered indicates an obstruction The principal channel is to the left of the buoy when returning from sea 2 Can Buoy This buoy indicates the port side of the channel when returning from sea It is cylindrical shape the color green and indicates odd numbers A can buoy with green and red horizontal bands top band green and not numbered indicates an obstruction The principal channel is to the right of the buoy when returning from sea 3 Lighted Buoy RED This buoy has flashing red light It indicat
99. s Faulty anti siphon valve Open the throttle 10096 and crank the engine When the engine starts immediately return the throttle to 1000 RPM Contact Crusader Marine Engines Dealer Check fuel for water or other contamination If contaminated drain and clean the fuel system 77 TROUBLESHOOTING 14 Malfunction Engine Overheats The following applies to engines equipped with Fresh Water Cooling FWC systems Insufficient engine temperature Engine oil pressure low 78 Possible Cause Loose or worn drive belt s Collapsed kinked or leaking hoses Transmission engine oil cooler plugged Faulty thermostat Sea water intake valve partially fully closed Restricted sea water pickup Faulty temperature sending unit or gauge Sea water pump impeller worn or damaged Coolant level low in the fresh water section of the cooling system Heat exchanger passages plugged with scales and debris Improper coolant mixture Faulty thermostat Faulty temperature sender Faulty oil pressure sending unit or gauge Oil level low Crankcase overfilled causing oil aeration Diluted or improper grade viscosity of oil 1510001 05 Corrective Action Adjust or replace the belts as necessary Replace the hoses Remove the water hoses and flush in opposite direction of the normal flow Replace the thermostat Open the valve completely Remove restriction Test and replace as necessary
100. s or can be anchored safely the engine should be shut off to prevent damage to the engine or transmission NOTICE Some boat builders may install their own alarm system It is recommended that the boat owner check with his or her boat dealer for an explanation of the particular alarm system upon initial delivery INSTRUMENTATION Boat manufacturers install many different types of instrumentation on boats Become familiar with the instrumentation on your boat and be aware of abnormal operating conditions The following is a brief explanation of typical instrumentation found on most boats 1 Tachometer indicates the engine RPM revolutions per minute 2 Engine Synchronizer twin engines only 3 Water Temperature Gauge indicates the engine coolant temperature 4 Oil Pressure Gauge indicates the engine oil pressure 5 Voltmeter indicates the battery voltage and charging system voltage 6 Hour Meter indicates the engine operating time 7 Fuel Level Gauge indicates the fuel tank level 8 Check Engine Lamp indicates a problem with the engine control system Crusader 28 51000105 OPERATING INSTRUCTIONS 5 CHECK ENGINE BILGE BLOWER 5 8 7 SWITCH IGNITION FUSES IGNITION SWITCHES e Figure 5 1 Typical Instrument Panel REMOTE CONTROLS THROTTLE Your boat may be equipped with one of many different types of remote controls available Ask you dealer for a description an
101. s facility Damage from participating in or preparing for racing or other competitive activity Water entering the engine cylinders or oiling system through the intake manifold system exhaust system submersion or in any manner if not caused by a Crusader manufacturing defect Water in starters Improper winterizing resulting in freezing and breaking of the engine block cylinder heads exhaust manifolds heat exchanger or other damage Repairs made necessary by normal wear rust electrolysis or corrosion or by the use of the parts or accessories which are either incompatible with the Crusader product or adversely affect its operation performance or durability Valve or valve seat grinding required because of wear Failure or damage due to lack of cooling water caused by starting the Product out of the water or by foreign material blocking the water inlets Cleaning of the engine fuel system due to water or dirt contamination of the boat fuel system Use of fuel and lubricants which are not suitable for use with or on the Product Refer to the Operation and Maintenance Manual Damage to the engine and or transmission caused by striking a submerged object This is considered a marine hazard 10 This Limited Warranty shall be governed by and construed and interpreted in accordance with the laws of 11 10 the State of Ohio without application of its conflicts of laws principles except only to the extent replaced or
102. 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 Figure 11 27 Shaft Mating Surface Check 8 Degree no resistance Down Angle NOTICE Some propeller shaft couplings may not have a shoulder on the mating surface On these installations use a straight edge to check the centerline alignment G0 ENGINES ENGINE MAINTENANCE 11 Figure 11 29 Centering Propeller Shaft 8 Degree Down Figure 11 31 Angular Alignment V Drives Angle 4 Check for any angular misalignment Hold coupling faces tightly together and check for a gap between the coupling faces with a 0 003 in 0 07 mm feeler gauge at 90 degree intervals Figure 11 30 Angular Alignment 8 Degree Down Angle Grande ENGINES 6190105 64 ENGINE MAINTENANCE 11 LOWER ENGINE Figure 11 32 Engine Mount Adjustment 5 If the coupling center lines are not aligned or if the coupling faces are more than 0 003 in 0 07 mm out of parallel adjust the engine mounts as follows UP or DOWN ADJUSTMENT Loosen the lag bolt 1 4 turn Use the mount adjusting tool or a 3 8 in 0 95 cm or 1 2 1 27 cm diameter rod through both sides of the adjusting sleeve to turn Turn the adjusting sleeve in
103. slowly to tension the belt Alternator Belt Tensioner Figure 11 21 6 0L Accessory Drive Belt Configuration Grande E G I E S ENGINE MAINTENANCE 11 Figure 11 22 Belt Tensioner 6 0L SERVICING RAW WATER PUMP IMPELLER 6 0L 6 0L IMPELLER KIT RP061022 The raw water pump impeller should be serviced every 50 hours or once a year whichever occurs first See Maintenance Schedule Locations A Figure 11 21 are access holes in order to loosen the raw water pump housing attaching bolts The bolts are secured in the pump by O rings and will not fall out during removal 1510001 05 57 ENGINE MAINTENANCE 11 5 0 5 7L ACCESSORY DRIVE BELT The Crusader 5 0 5 7L engines use a single serpentine belt to drive the engine water circulation pump sea water pump and the alternator Belt Tensioner Crankshaft Pulley Figure 11 23 5 7L Accessory Drive Configuration Left Hand Rotation Belt Belt Idler Tensioner B Water A 2 rnator Figure 11 23A 5 7L Accessory Drive Belt Configuration Right Hand Rotation Figure 11 24 Belt Tensioner 5 0 5 7L DRIVE BELT REPLACEMENT 5 0 5 7L 5 0 5 7L SERPENTINE BELT LH R066028 5 0 5 7L SERPENTINE BELT RH R066029A 1 Note the routing of the belt before removing 2 Using a 15 mm box wrench or socket turn the belt tensioner to relieve the tension on the belt Slide the b
104. st owner purchasing at retail and all subsequent owners of every Crusader Model Years 2003 2008 inboard engine that the emissions control devices on Crusader inboard marine engines are free from defects in materials and workmanship when manufactured and will remain so for a period of two 2 years from the date of delivery to the first owner purchasing the engine at retail or from the date the engine is first placed into service for demonstration or any other purpose prior to sale to the first owner purchasing the engine at retail 2 Pursuant to the California Code of Regulations Title 13 Chapter 9 Article 4 78 2445 1 Crusader warrants that each Crusader engine is designed built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code and is free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in Crusader s application for certification 3 Any part covered under this Warranty that is not scheduled for replacement as required maintenance in the written instructions to be found within the Crusader Owners Operators Manual is warranted for the period of two 2 years If the part fails during the period of warranty coverage Crusader will repair or replace the defective part at any Crusader warranty station
105. tect the engine or transmission during an over temp or low oil pressure condition When in Power Reduction mode the ECM will allow normal engine performance up to 2000 RPM Above 2000 RPM the ECM allows fuel delivery through only half of the fuel injectors Once the RPM is brought down below 1200 RPM normal engine operation is restored until the RPM exceeds 2000 RPM The feature allows maneuverability of the boat while removing the possibility of high engine speed operation until the problem is corrected On twin engine applications if configured correctly by the installer BOTH engines will be limited to 2000 RPM NOTICE If it is not possible to safely shut off the engine s return the engine s to idle speed Once returned to idle the ECM will allow the engine s to operate normally below 2000 RPM High Engine Coolant Temperature During operation if the engine coolant temperature exceeds 220 104 8 C the engine enters Power Reduction mode and illuminates the WATER TEMP portion of the warning light cluster if equipped A warning buzzer will also sound if equipped VS Figure 4 2 WATER TEMP Light Illuminated 2 U510001 05 ELECTRONIC FUEL INJECTION INFORMATION 4 Low Engine Oil Pressure During operation if the engine oil pressure drops below 10 psi with the engine above 2000 RPM the engine enters Power Reduction mode and illuminates the OIL
106. ter from the bowl 5 Install new filter and seal Lubricate the new seal with a fuel resistant O ring lubricant Then screw bowl back onto the head unit 6 Open fuel shut off valve 7 Prime the fuel system Refer to procedures in this section 8 Turn the key to START position and crank the engine until it starts or 30 seconds elapse 9 Repeat step 8 if the engine fails to start 10 After the engine starts check for leaks and repair as necessary WARNING Make sure there are no fuel leaks before closing the engine hatch Priming Fuel System To prime the fuel system cycle the ignition key 3 times using the following procedures 1 Turn ignition key to ON position for 5 seconds 2 Turn ignition key OFF 3 Pause for 10 seconds 4 Repeat steps 1 3 three times Crank the engine until it starts or 30 seconds elapse If the engine does not start repeat the priming procedures Crusader E N E S ENGINE MAINTENANCE 11 FLAME ARRESTOR At specified intervals the flame arrestor should be checked for blockage caused by dirt or other foreign material Loosen the clamp securing the flame arrestor to the air intake tube or throttle body Remove the flame arrestor Clean the flame arrestor with solvent and dry with compressed air Reinstall the flame arrestor and tighten the clamp s securely FLAME ARRESTOR FASTENERS FLAME ARRESTOR THROTTLE BODY Figure 11 17 Flame
107. the engine 4 Slide the bowl downward over the suspended filter element It may be necessary to pull the unit to one side in order to remove the FCC bowl 5 Remove the fuel filter element from the suspended pump by gripping the fuel pump with one hand and pulling the filter element downward with the other hand 14 Start the engine and inspect for fuel leaks Correct any leaks prior to operating the engine any further DO NOT ATTEMPT TO SERVICE ANY OTHER PARTS 6 Push on new filter element part number ON THIS UNIT RP080026 over the electric fuel pump Grussder 11000500000 FCC Service Instructions FCC Clamp on Canister WARNING Extreme caution must be exercised when servicing the fuel system The fuel system operates under high pressure Use caution when removing or replacing components as residual pressure may be present Draining the FCC Bowl ENGINE OFF 1 2 Disconnect the two wire electrical connector Remove the 7 16 plug and drain the bowl contents into an approved container CAUTION Both fuel and water will drain from the FCC bowl 3 Apply pipe sealant suitable for use with gasoline to the threads of the 7 16 plug 4 Tighten the 7 16 plug 5 Reconnect the two wire electrical connector Cycle the ignition key several times to run the electric fuel pumps and fill the FCC bowl with fuel Inspect the drain plug area for leaks Correct an
108. ting difficulties vapor lock low speed stalling e Corrosion of metal parts Excessive wear and damage to internal engine parts Fuel permeation through flexible fuel lines Deterioration of some nonmetallic materials The adverse effects of alcohol are more severe with methanol and are worse with increasing alcohol content If gasoline containing alcohol is used or if the presence of alcohol is uncertain more frequent inspections of the complete fuel system are required Any sign of fuel leakage or deterioration must be repaired immediately before further engine operation CAUTION Fire and Explosion Hazard Gasoline is extremely flammable and highly explosive and if ignited can cause serious bodily injury or death Careful inspection of the entire fuel system including but not limited to fuel tanks fuel lines fuel filters and all fittings is mandatory especially after periods of storage Replace any component that shows signs of leakage corrosion deterioration swelling hardening or softening NOTICE Some gasolines contain an octane enhancing additive called methylcyclopentadlenyl manganese tricarbonyl MMT and they should not be used These fuels may reduce spark plug life and engine performance may be effected L510001 05 37 OIL REQUIREMENTS 10 ENGINE OIL RECOMMENDATIONS Use of Supplemental Additives Engine oils meeting Crusader Marine Engines recommendations already contain a bal
109. tion Record Propeller Size Rotation and WOT WOT RPM Diameter Pitch Rotation Record Fuel Pressure WOT Trouble Codes Checked Trouble Codes Cleared Dealer Reviewed Warranty with Owner DATE OF SALE 2ND Owner 1 1 DATE OF SALE 151 Owner 1st Operator ___ ____ New Owner Previous Owner NAME NAME ADDRESS ADDRESS CITY STATE ZIP CITY STATE ZIP hereby certify the Pre Delivery Checklist on engine and have corrected any abnormality revealed by this inspection Technician Signature Dealer amp Date Seller s Signature amp Date Purchaser s Signature amp Date Grande ENGINES 6190105 94 NOTES 19 Grande EN G I N 5 1510001 05 93 Pleasurecraft Engine Group 1737 Highway 76 East Little Mountain SC 29075
110. to coat the boat bottom with antifouling paint to prevent the build up of marine growth Contact your dealer for advice on these requirements in your area L510001 05 33 CONDITIONS AFFECTING OPERATION 6 PROPELLER SELECTION If full throttle RPM is above or below the recommended range as stated in ENGINE SPECIFICATIONS the Best all around performance and maximum engine life is propeller must be changed to prevent loss of achieved when the engine is propped to run near the top performance A one inch change in either the pitch of but within the recommended full throttle RPM range or diameter of a given propeller will generally change with a normal load See ENGINE SPECIFICATIONS for engine RPM by 150 to 250 RPM rated full throttle RPM for your model engine Generally gross weight total weight of the entire ENGINE RPM CHART boat including full fuel and water optional equipment Minimum passengers and other miscellaneous gear is one of Model Full Load eser vas the major factors and should be one of the primary considerations when selecting a propeller Other factors to take 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 load will cause an RPM loss additional equipment passengers etc CAUTION Prolonged WOT operation will shorten the life of your engine
111. uel pressure regulator is located inside the FCC therefore does not require a fuel return line from the fuel rail Excess fuel not used by the engine returns to the FCC bowl The fuel delivered to the engine by the FCC is filtered by a filter and water separator element which surrounds the high pressure pump inside the FCC bowl As indicated above fuel enters the FCC bowl from two 2 locations the low pressure pump initial input and the fuel pressure regulator unused recirculating fuel Fuel exits the FCC bowl at two 2 locations the high pressure output to the fuel injection system and all excess fuel in the FCC bowl is routed back to the tank via the return line ENGINE MAINTENANCE 11 FUEL CONTROL CELL PRIMARY FUEL FILTER LOW PRESSURE FUEL PUMP V On NS V Lay Figure 11 13 Fuel Control FCC Fuel System Typical Servicing the FCC The frequency of draining the water or replacing the filter element is determined by the contamination level of the fuel Replace the filter element at least once a year or when a loss of power is noticed whichever occurs first WARNING Improper use installation or servicing may cause an explosion or fire resulting in bodily injury or death This unit should only be serviced by a qualified technician Read and follow all instructions before proceeding Run the engine and check for
112. y leaks prior to operating the engine Start the engine and inspect for fuel leaks Correct any leaks prior to operating the engine any further Filter Element Replacement ENGINE OFF FCC SERVICE KIT RP080026 1 Disconnect the two wire electrical connector Remove the 7 16 plug and drain the bowl contents into an approved container CAUTION Both fuel and water will drain from the FCC bowl 3 4 Remove the canister retaining clamp Slide the canister downward over the suspended filter element It may be necessary to pull the unit to one side in order to remove Remove the fuel filter element from the suspended pump by gripping the fuel pump with one hand and pulling the filter element downward with the other hand Visually inspect all internal components i e hoses wires etc Push on new filter element part number RP0800296 over the electric fuel pump ENGINE MAINTENANCE 11 CENA gt O RINGS FUEL PRESSURE REGULATOR FUEL M FUEL FILTER Figure 11 15 Fuel Control Cell FCC Clamp on Canister Typical CAUTION The mounting head O ring grooves may be damaged by using sharp steel tools to remove these O rings 9 10 11 12 13 14 15 16 Install the new O rings in the same location Lubricate the new O rings with a fuel resista

Crusader 5.0L/5.7L/6.0L/8.1 MPI 8.1L MPI(HO) user manual(2)

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