Crusader Challenger 5.7L Catanium CES User manual

OWNER’S OPERATION
and
MAINTENANCE MANUAL

This Page
Was Intentionally
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Part Number - L510032-16 Printed 01/16
Thank you for your selection of Crusader Challenger for your boating needs. We welcome you to Team Pleasurecraft
Engine Group, which puts you in the company of tens of thousands of boaters who have relied on Pleasurecraft
inboards as their power of choice for over 30 years.
When you chose Challenger, you selected the utmost in premium power for your boating application. Pleasurecraft
Engine Group is the world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting
edge technology. Over the years, we have introduced many breakthrough innovations that quickly became industry
standards. The pyramidal exhaust system, light-weight transmission, computerized engine control and the Fuel Control
Cell (FCC) are all Pleasurecraft Engine Group innovations. No matter which Challenger model you purchased, you can
be sure it is equipped with the latest in modern technology for added performance and durability.
READ THIS MANUAL THOROUGHLY
Before starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand any
portion of the manual, contact your Dealer for clarication or assistance. Ask your Dealer for a demonstration of actual
starting and operating procedures.
The descriptions and specications contained in this manual were in e󰀨ect at the time of printing. Pleasurecraft Engine
Group’s policy of continued improvement reserves the right to change specications or design without notice and
without obligation.
This manual will cover the following year of manufacture Challenger Series engines:
Year Model Year Model
*2016 Challenger *2016 Challenger Salt Series
5.7L Catanium™ CES 5.7L Catanium™ CES
*2016 Challenger *2016 Challenger Salt Series
6.0L Catanium™ CES 6.0L Catanium™ CES
*2016 Challenger *2016 Challenger Salt Series
6.0L HO Catanium™ CES 6.0L HO Catanium™ CES
2016 Challenger
6.2L
* Pleasurecraft Engine Group’s Catanium™ Clean Emission System is available to reduce emissions without
diminishing performance. Catanium™ CES is patented catalyst technology which uses precious metals to
create clean emissions and greatly reduce dangerous carbon monoxide gases.

WARNING
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects or
other reproductive harm.
PROPOSITION 65

1
L510032-16
INTRODUCTION ............................................................................................................................... 3-9
Registration Information (Warranty Registration Card is located at the back of this manual) ........................ 3
3-Year Transferable Limited Warranty ..................................................................................................... 4
Federal/California Emission Control Warranty Statement ......................................................................... 5
Crusader Challenger Inboard Marine Engine General Emissions Warranty Coverage .................................. 6
Safety Information ................................................................................................................................ 9
Replacement Parts ............................................................................................................................... 9
Safety Warnings ................................................................................................................................... 9
BOATING RESPONSIBILITY ......................................................................................................... 10-12
Carbon Monoxide Hazard .................................................................................................................... 10
Safe Boating Suggestions ................................................................................................................... 11
Water Wisdom .................................................................................................................................... 11
Operation and Maintenance ................................................................................................................. 11
Rules of the Road ............................................................................................................................... 12
ENGINE IDENTIFICATION ............................................................................................................. 13-14
Engine Identication ............................................................................................................................ 13
Owner Identication and Registration Information .................................................................................. 13
Engine Model Identication / Advisory ................................................................................................... 14
ELECTRONIC FUEL INJECTION INFORMATION ................................................................................ 15
Electronic Fuel Injection System .......................................................................................................... 15
OPERATING INSTRUCTIONS ........................................................................................................ 16-22
Engine Alarm System .......................................................................................................................... 16
Instrumentation ................................................................................................................................... 17
Electronic Speed Control ..................................................................................................................... 17
Starting Engine (Fuel Injected Engines) ................................................................................................ 17
Shifting Transmission .......................................................................................................................... 19
Stopping Engine ................................................................................................................................. 20
Freezing Temperature Operation .......................................................................................................... 20
Operation in High Debris Areas ............................................................................................................ 20
Challenger Speed Control System .................................................................................................. 21-22
CONDITIONS AFFECTING OPERATION ........................................................................................ 23-24
Weight Distribution ............................................................................................................................. 23
Boat Bottom ....................................................................................................................................... 23
Propeller Selection .............................................................................................................................. 23
ENGINE BREAK-IN PERIOD .............................................................................................................. 24
25-HOUR ENGINE INSPECTION ........................................................................................................ 25
FUEL REQUIREMENTS ..................................................................................................................... 26
Gasoline Requirements ....................................................................................................................... 26
Gasoline Containing Alcohol ................................................................................................................ 26
OIL REQUIREMENTS ........................................................................................................................ 27
Engine Oil Recommendations .............................................................................................................. 27
Transmission and “V”-Drive Oil Requirements ....................................................................................... 27
ENGINE MAINTENANCE ............................................................................................................... 28-51
Engine Maintenance ........................................................................................................................... 28
Checking Fluid Levels .................................................................................................................... 28-30
Lubrication ......................................................................................................................................... 30
TABLE OF CONTENTS

2L510032-16
Electrical System Relay and Fuse Block ............................................................................................... 31
Electrical System Fuses ............................................................................................................. 31
Boat’s Ignition Fuse ................................................................................................................... 31
Electrical System Wiring and Connectors ...................................................................................... 31
Battery .................................................................................................................................... 31
Fuel System Description ............................................................................................................ 36
Fuel Control Cell (FCC) Fuel System ............................................................................................ 36
In-Tank High Pressure Fuel Pump System ................................................................................. 36
Servicing the FCC ..................................................................................................................... 37
Primary Fuel Filter (FCC Clamp-on Canister) ................................................................................. 37
Servicing Fuel Pre-Filter ............................................................................................................. 39
Priming Fuel System ................................................................................................................. 39
Flame Arrestor ......................................................................................................................... 39
Accessory Drive Belt ............................................................................................................. 40
Servicing Raw Water Pump Impeller ............................................................................................. 41
Changing Oils .......................................................................................................................... 42
Engine Alignment ................................................................................................................. 43-46
Engine Maintenance Log ............................................................................................................ 47
Maintenance Schedule .......................................................................................................... 48-49
Visual Inspection ...................................................................................................................... 50
Engine Fluid Capacities ............................................................................................................. 50
Transmission Fluid Capacities ..................................................................................................... 50
Filter and Accessory Requirements .............................................................................................. 51
ENGINE SPECIFICATIONS ................................................................................................... 52-54
OUT-OF-SEASON STORAGE ................................................................................................ 55-57
Engine Storage ........................................................................................................................ 55
Draining Instructions .................................................................................................................. 56
Battery Storage ........................................................................................................................ 56
Out-of-Season Engine Warm-Up ................................................................................................. 57
Recommissioning After Storage ................................................................................................... 57
TROUBLESHOOTING .......................................................................................................... 58-60
WATER FLOW DIAGRAMS ................................................................................................... 61-69
HEATER CONNECTIONS ................................................................................................... 70-71
INSTRUMENTATION WIRING DIAGRAM ..................................................................................... 72
LITERATURE .......................................................................................................................... 73
FORMS............................................................................................................................... 74-77
NOTES ................................................................................................................................... 78
WARRANTY/REGISTRATION CARD
TABLE OF CONTENTS

3
L510032-16
REGISTRATION INFORMATION
(Warranty Registration Card is located at the
back of this manual)
Shortly after your purchase is registered with Crusader
Challenger, you will be mailed your Warranty Card and
a Customer Survey. We appreciate your feedback and
encourage you to ll out the survey after you have had a
chance to run your boat for several weeks. We take this
input very seriously, and have implemented many of the
ideas our customers have given us through this survey.
You may also visit our web site at www. pleasurecraft.
com.
Again, thank you for choosing Crusader Challenger. We
sincerely wish you happy days on the water.
INTRODUCTION - 1

INTRODUCTION - 1
3 YEAR TRANSFERABLE LIMITED WARRANTY
Pleasurecraft Marine Engine Co., through its Crusader Challenger Engines Division (“Challenger”), warrants its new products to be free from defects in material and workmanship
under normal use and service conditions, to the rst registered owner or registered user, as well as all subsequent users who, in accordance with Challenger’s warranty transfer
policy, have received within 30 days of a sale transaction involving the product a transfer of any remaining period of coverage under this warranty. The obligation of Challenger
under this warranty shall be limited to the repair or replacement with new or reconditioned components, at Challenger’s option, of any product, or parts thereof, which have failed
during the warranty period specied below and are demonstrated upon examination to have failed due to defective material and/or workmanship.
WARRANTY COVERAGE; TERM
This warranty is extended only to the rst registered owner or registered user, as well as all subsequent users who, in accordance with Challenger’s warranty transfer policy, have
received within 30 days of a sale transaction involving the product a transfer of any remaining period of coverage under this warranty, as specied below.
All components, other than those itemized below and those components that are warranted by Challenger’s suppliers, are warranted, solely for non-commercial use, for a period
of 3 years or 300 hours of use, whichever rst occurs, from the earlier of (1) the date of sale to the rst registered owner or registered user, or (2) from the date the engine is rst
placed into service for demonstration or any other purpose prior to the sale of the engine to the rst owner purchasing the engine at retail, as well as to all subsequent users who,
in accordance with Challenger’s warranty transfer policy, have received a transfer of any remaining portion of this warranty coverage within 30 days of any subsequent sale of the
product. In the case of commercial use of the product, the term of this warranty shall be the shorter of (a) a period of 6 months from the date of sale to the rst registered owner or
registered user, or (b) the expiration of 200 hours of use.
Components not covered under this warranty:
(1) Water pump impellers are not covered by this warranty.
(2) Seals, gaskets, o-rings, and other materials a󰀨ected by time are not covered by this warranty if their e󰀨ectiveness is reduced by an extended storage period prior to sale or use
of the product.
(3) Items such as, but not limited to, lubricants, spark plugs and other items which are normally frequently replaced as part of routine maintenance.
NO OTHER WARRANTY GIVEN
The obligations set forth in the preceding paragraphs are Challenger’s sole obligation and the owner’s exclusive remedy. Challenger makes no other express warranty. Any
implied warranty of merchantability or tness for a particular purpose that may be applicable to this product is limited in duration to the duration of this warranty. Some States do
not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
No distributor, dealer, agent or employee of Challenger is authorized to grant any other or further warranty or incur any additional warranty obligation on Challenger’s behalf in
connection with the sale of its products. Any qualication or restriction contained herein which is prohibited by any law of mandatory application shall be deemed to be deleted from
this warranty; however, such deletion shall have no e󰀨ect on the remaining provisions hereof, all of which shall remain in full force and e󰀨ect.
REMEDIES
The obligation of Challenger set forth in the rst paragraph of this warranty shall be the exclusive remedy for any breach of warranty hereunder, and any owner or user’s sole
remedy in the event of breach of the warranties is repair or replacement of the product or any warranted part thereof as set forth in this warranty: with this sole exception,
Challenger shall not be liable for any direct or indirect, incidental or consequential damages, including without limitation, any damages for property damage, loss of use or loss of
prots, loss of income, inconvenience, trailering, towing, haul out, launch and/or any other in and out of water expenses, storage charges, dockage charges, expenses to deliver
or pick up the product being warranted to and from the dealer, telephone expenses, lodging expenses, travel expenses, mechanic travel time and mileage, damage caused by
any occurrence of an insurable nature, rental of substitute equipment of any type, removal and replacement and/or modication of any boat parts to facilitate repairs, moving of
furniture, carpets, cleaning, painting, carpenter work, or re-delivery charges. Some States do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
Any owner or user hereby waives for himself/herself/itself and his/her/its successor 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 Challenger’s liability exceed the purchase price of the product(s) which is actually paid to Challenger.
OBTAINING PERFORMANCE UNDER WARRANTY
Challenger’s warranty registration form should be prepared by your selling dealer, executed by you and the dealer, and mailed by you to Challenger within 30 days after the date
of your purchase of the product. Upon receipt of the warranty registration form, Challenger will issue to you a personalized owner’s registration card which will be mailed directly to
you. If the owner’s registration card is not received within 8 weeks after the date of purchase, please write to Challenger at the address set forth below.
At the time that a claim for warranty service is made, the owner’s registration card should be presented to the person or entity providing warranty service. Authorized Challenger
dealers or distributors are entitled to be reimbursed by Challenger for some or all of the expense of warranty repairs; thus, service under the terms of this warranty will be
performed by an authorized Challenger dealer or distributor without charge for established at rate labor or replacement parts, other than items not covered by the warranty, such
as, but not limited to, water pump impellers, seals, gaskets, o-rings and other materials a󰀨ected by time if their e󰀨ectiveness is reduced by an extended storage period prior to sale
or use of the product, and lubricants, spark plugs and other items which are normally frequently replaced as part of routine maintenance. Charges for additional non-warranty work
and/or additional dealer charges for labor relative to warranty work in excess of at rate must be paid for by the owner.
Prior authorization in writing must be obtained from Challenger for any warranty repairs over $50.00 and in all cases where the owner fails to establish the purchase and warranty
expiration dates with the owner’s registration card sent upon receipt of the warranty registration form by Challenger. While failure to present the owner’s registration card will
not prevent you from obtaining coverage hereunder, this warranty shall not be e󰀨ective and, therefore, cannot be honored until the product purchase date can be conrmed by
Challenger. If the card is lost, communicate with Challenger at the address listed below, and, for a processing fee of $10.00, a new owner’s registration card will be issued to you.
Any questions concerning service, parts or this warranty should be directed to your selling dealer. If your dealer is unable to assist or if you relocate or are travelling or need a
referral to your nearest dealer contact: Pleasurecraft Marine Engine Co., P.O. Drawer 369, Little Mountain, SC 29075 ([phone]).
FAILURES EXCLUDED FROM WARRANTY
This warranty will not apply to any failure which results from accidents, sinking, re, neglect, abuse or abnormal service or use, such as racing, towing or operation in water of
insu󰀩cient depth, or to any failure resulting from improper installation, improper adjustments, repairs or improper delivery service, or to any failure resulting from the use of parts,
fuels, oils or lubricants not suitable for use with the product and/or materials or parts not approved by Challenger. This warranty does not apply to any engine or drive which has
been modied, or altered, or repaired in such a manner as, in the opinion of Challenger, to a󰀨ect its stability, reliability or performance. Further, this warranty will not apply to
product failure resulting from (1) use of non-recommended lubricants or fuels, (2) failure to follow maintenance or lubrication schedules, (3) failure caused or contributed to by
improper or contaminated fuel, (4) failure caused by water intrusion, salt corrosion to external components, or improper installation or misapplication of the engine or drive, (5)
the owner’s or operator’s failure to exercise due or normal care and precaution, (6) failure of components and/or assemblies that are warranted by Challenger suppliers, and (7)
damage resulting from the owner’s or operator’s failure to timely replace failed water pump impellers, seals, gaskets and o-rings.
OWNER’S RESPONSIBILITY
Performance under this warranty shall be conditioned upon the rst registered owner’s or registered user’s compliance with the following requirements:
(1) Owner or user shall verify that the pre-delivery service has been performed, all requested information recorded and that the selling dealer has signed the warranty registration.
(2) Owner or user shall promptly mail the warranty registration to Challenger after accepting delivery.
(3) Owner or user shall follow the instructions in the owner’s manual regarding operation, break-in, lubrication and fuel.
(4) Owner or user shall follow or comply with the maintenance schedule, operation limits, and lay up instruction, as outlined in the owner’s manual.
CHOICE OF LAW
This limited warranty shall be governed by, and construed and interpreted in accordance with, the local laws of the State of Ohio (without application of its conicts of laws
principles), except only to the extent replaced or precluded by other law of mandatory application.
GENERAL
This warranty gives you specic legal rights, and you may also have other rights which vary from State to State.
The Challenger Federal/California Emissions Warranty and Federal/California Emissions Control Warranty Statement are separate documents included in the owner’s manual.
Any questions concerning the Emissions Warranty can be obtained by calling [phone].
Challenger’s policy is one of continued improvement of its products, and Challenger hereby reserves the right to improve and change the design and production of any of its
products without assuming any obligation to modify products previously manufactured and/or sold.

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INTRODUCTION - 1
PLEASURECRAFT MARINE ENGINE CO.
FEDERAL/CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The United States Environmental Protection Agency (“USEPA”), the California Air Resources Board
(“CARB”) and Pleasurecraft Marine Engine Co., through its PCM Engines Division (“PCM”), are pleased to
explain the emission control system warranty on your inboard marine engine manufactured after January 1,
2008 for CARB and after January 1, 2011 for USEPA. Nationally, new inboard engines must be designed,
built and equipped to meet USEPA’s and CARB’s emissions and stringent anti-smog standards. PCM 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 warrantable condition exists, PCM will repair your inboard engine at no cost to you,
including diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGE:
Select emission control parts of inboard marine engines (manufactured after January 1, 2008 for CARB and
after January 1, 2011 for USEPA) are warranted for 3 years or 480 hours of use, whichever rst occurs.
However, warranty coverage based on the hourly period is only permitted for engines that are equipped with
appropriate hour meters as dened in California Code of Regulations Title 13, Chapter 9, Article 4.7 §2441(a)
(13) or the equivalent. If any emission-related part on your engine is defective under warranty, the part will
be repaired or replaced by PCM.
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. PCM recommends that you retain all receipts covering maintenance on your
inboard engine, but PCM cannot deny warranty 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 PCM may deny you warranty
coverage if your inboard engine or a part has failed due to abuse, neglect, improper maintenance or
unapproved modications.
– You are responsible for presenting your inboard engine to an authorized PCM dealer as soon as a
problem exists. The warranty repairs will be completed in a reasonable amount of time, generally within 30
days.
If you have any questions regarding your warranty rights and responsibilities, you should contact PCM at
[phone].

6L510032-16
INTRODUCTION - 1
PLEASURECRAFT MARINE ENGINE CO.
GENERAL EMISSIONS WARRANTY COVERAGE
(for engines manufactured after January 1, 2008 for CARB and after January 1,
2011 for USEPA)
1. Pleasurecraft Marine Engine Co., through its PCM Engines Division (“PCM”), warrants to the rst owner
purchasing at retail, and all subsequent owners, of every PCM inboard marine engine manufactured after
January 1, 2008 for CARB and after January 1, 2011 for EPA, that the emissions control devices on PCM
inboard marine engines are free from defects in materials and workmanship when manufactured and will
remain so for a period of 3 years or 480 hours of use, whichever rst occurs, from the earlier of the date of
sale to the rst owner purchasing the engine at retail or the date the engine is rst placed into service for
demonstration or any other purpose prior to sale to the rst owner purchasing the engine at retail.
2. Pursuant to the Code of Federal Regulations 40 CFR Part 1045 and Part 1068 and California Code of
Regulations Title 13, Chapter 9, Article 4.7§ 2445.1, PCM warrants that each PCM engine is designed,
built and equipped to conform with all applicable regulations adopted by USEPA and CARB pursuant to its
authority in Chapters 1 and 2, Part 5, Division 26 of the California 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 PCM’s application for certication.
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 PCM owners/operators manual, is warranted for the period of 3
years or 480 hours of use, whichever rst occurs. If the part fails during the period of warranty coverage,
PCM will repair or replace the defective part at any PCM 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 of 3 years or 480 hours of use, whichever rst occurs.
4. Any part covered under this warranty that is scheduled only for regular inspection in the written instructions
to be found within the PCM owners/operators manual, is warranted for the period of 3 years or 480 hours
of use, whichever rst occurs. If the part fails during the period of warranty coverage, PCM will repair or
replace the defective part at any PCM 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 of 3 years or 480 hours of use, whichever rst occurs.
5. Any part covered under this warranty that is scheduled for replacement as required maintenance in the
written instructions to be found within the PCM owners/operators manual will be warranted for the period
of time before the rst scheduled replacement date for that part. If the part fails before the rst scheduled
replacement, PCM will repair or replace the defective part at any PCM 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 rst scheduled replacement date for
the part.
6. Replacement of any part under this warranty with a PCM-supplied part, will not shorten nor extend the
warranty period(s) stated in paragraphs 1 through 4 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 PCM
warranty station.

7
L510032-16
INTRODUCTION - 1
8. To insure prompt repair under this warranty, PCM will maintain a supply of warranted parts su󰀩cient 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 PCM without charge to the owner.
9. Parts covered under this warranty are:
Fuel Metering System
A. Fuel Injectors
B. Fuel Pressure Regulator
C. Manifold Absolute Pressure Sensor
D. Throttle Position Sensor
E. Throttle Body - Port Fuel Injection Models
F. Coolant Temperature Sensor
G. Intake Valves
H. Oxygen Sensors
Air Induction System
A. Intake Manifold
B. Air Filter (Flame Arrestor)
Ignition System
A. Spark Plugs
B. Electronic Ignition System
C. Ignition Coil and/or Control Module
D. Ignition Wires
10. Exclusions: The repair or replacement of any warranted part otherwise eligible for coverage under this
warranty may be excluded from such warranty coverage if PCM 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 replacement of the part.
11. PCM original equipment parts are “identical in all material respects to that part as described in the engine
manufacturer’s application for certication”. The use of any replacement parts not supplied by PCM may
not meet this requirement and will be grounds for disallowing a claim made under this warranty. PCM will
not be liable under this warranty or provide warranty coverage for product failures caused by parts other
than PCM original equipment parts.
12. If you have any questions regarding your warranty rights and responsibilities, or the location of PCM
warranty stations near you, you should contact PCM at [phone].
Lubrication System
A. Oil Pump and Internal Parts
Positive Crankcase Ventilation (PVC) System
A. PCV Valve
B. Oil Filler Cap
Exhaust System
A. Exhaust Manifold(s)
B. Exhaust Riser(s)
C. Exhaust Valves
D. Catalytic Converters
Miscellaneous Items Used on Above Systems
A. Hoses, clamps, ttings, tubing, sealing gaskets
or devices and mounting hardware
B. Electronic Controls
C. Electronic Control Module
D. Pulleys, belts and idlers

8L510032-16
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INTRODUCTION - 1

9
L510032-16
SAFETY INFORMATION
“Safety Warnings” and additional information or
instructions are used to alert the installer/operator of
possible safety hazards in performing certain service
or maintenance procedures incorrectly or carelessly.
DANGERS and WARNINGS are accompanied by the
international HAZARD symbol:
These “Safety Warnings” alone cannot eliminate
the hazards that they signal. Strict compliance with
these warning instructions while performing service
and maintenance procedures, plus “common sense”
operation, are major accident prevention measures.
REPLACEMENT PARTS
Use of replacement parts (i.e. automotive, after-market,
etc.) in the electrical, ignition and fuel systems, which
are not U.S. Coast Guard approved, could cause a re
or explosion hazard and should be avoided.
Always request that genuine Crusader Challenger
Engines replacement parts be used in any repairs or
maintenance being performed on your engine(s).
DANGER
Electrical, ignition and fuel system components are
designed and manufactured to comply with U.S.
Coast Guard rules and regulations to minimize the
possibility of re or explosion hazard.
DANGER
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
SAFETY WARNINGS
WARNING
Indicates a potential hazard which could result in personal injury.
CAUTION
Indicates a hazard which could result in damage to equipment.
WARRANTY NOTICE: Indicates a possible warranty exclusion.
INTRODUCTION - 1
IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily.

10 L510032-16
BOATING RESPONSIBILITIES - 2
CARBON MONOXIDE HAZARD
Carbon monoxide is produced when anything that
contains carbon, such as gasoline, 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 ame devices like cooking ranges,
heaters and charcoal grills also produce carbon
monoxide.
Carbon monoxide accumulation, in and around boats
is a󰀨ected 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 qualied
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.
DANGER
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!
To nd out more about making boating safer, including
how you can prevent carbon monoxide poisoning on
recreational boats, contact:
National Marine Manufacturers Association
200 East Randolph Drive
Suite 5100
Chicago, IL 60601-6528
www.nmma.org
312-946-6200
United States Coast Guard
O󰀩ce of Boating Safety
CG Headquarters G-OPB-3
2100 Second Street SW
Washington, DC 20593
www.uscgboating.org
202-267-0984
American Boat & Yacht Council, Inc.
3069 Solomon’s Island Road
Edgewater, MD 21037-1416
www.abyc.com
410-956-1050

11
L510032-16
BOATING RESPONSIBILITIES - 2
SAFE BOATING SUGGESTIONS
The nation’s waterways are becoming increasingly
crowded and, in order to enjoy them safely, the operator
should acquaint himself/herself with safe boating
practices. Boating safely and seamanship courses are
o󰀨ered by the following national and state organizations:
• Power Squadrons
• Coast Guard Auxiliary
• Red Cross
• State, provincial or local agencies in charge of
water safety enforcement
Crusader Challenger Engines highly recommends that
all power boat operators attend one of these courses.
To help locate a course being o󰀨ered 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.
• Do not consume alcoholic beverages or take
illegal drugs when operating a boat. Some state
laws apply to boats as well as motor vehicles.
• File a “oat 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.
The following is a list of suggested safety equipment
and spare parts which may be useful in case of an
emergency:
• Approved personal otation devices (life jackets);
one for each person on board.
• Approved throwable personal otation device for
man-overboard protection.
• Approved re extinguishers.
• Signal devices: ares, spotlight, signal ag and
horn or whistle.
• Crusader Challenger Engines’ “Onboard Kit,”
plus spare fuses, bulbs, batteries, etc. Tools
necessary for minor repairs.
• Spare propeller.
• Anchor and anchor line.
• First aid kit and rst aid book.
• Ship-to-shore radio, compass and chart of the
area in which you are traveling.
• Manual bilge pump and spare drain plugs.
• Waterproof 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 Challenger engine. When service and
maintenance are required, return to your authorized
Crusader Challenger Engine Certied Dealer.

12 L510032-16
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
returning from sea. It is conical shape, the
color red and indicates even numbers. A
nun buoy with red and green horizontal
bands (top band red), 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 a
ashing red light. It indicates the starboard
side of the channel when returning from
sea.
4. Lighted Buoy (GREEN): This buoy has
a quick ashing green light. It indicates
the port side of the channel when returning
from sea. The quick ashing light indicates
special caution required.
BOATING RESPONSIBILITIES - 2
Boat Capacity
• Load only to manufacturer’s specications.
• Distribute load evenly; keep it low.
• Passengers should only ride on the parts of the
boat that are designed for that purpose.
• If water is rough, carry fewer passengers.
Observe the Rules of the Road
PORT (Left) - Leaving the harbor with green buoys to
your right.
STARBOARD (Right) - Entering the harbor with red
buoys to your right.
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 = I 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
entering 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
res, pilot lights and smoking materials.
4. Do not overload tanks.
5. Keep lling nozzles in contact with the ll pipe to
prevent sparks.
6. Secure the ll cap tightly; wipe away any
spillage.
7. Ventilate all components for a minimum of ve
minutes before starting engines.
8. Keep fuel lines and bilges clean.
2
5
Small Craft
Winds up to
38 MPH
Gale Winds
38 - 54 MPH
Storm Winds
over 55 MPH
Hurricane
Winds over
63 MPH
Storm Warning Signals - Pennants (by day)
Lights (by night)
Keep to Right
in narrow
channels.
Boat being overtaken
has right of way.
Overtaking boat must
stay clear.
Yield to boats
approaching in
this area.

13
L510032-16
ENGINE IDENTIFICATION - 3
ENGINE IDENTIFICATION
When ordering service parts or obtaining information,
always give the engine model and the serial number.
This information can be found on the following decal.
PLEASURECRAFT MARINE ENGINE CO.
MODEL
FIRING ORDER
SERIAL
THIS ENGINE CONFORMS TO ALL APPLICABLE U.S. GOVERNMENT
STANDARDS AND INTERNATIONAL BODENSEE SHIPPING
COMMISSION
STANDARD CERTIFICATION NO. M14 34 1 01 01
FOR MARINE ENGINES AT THE DATE OF MANUFACTURE.
LITTLE MOUNTIAN, SC 29075
MFR DATE:
Figure 3-1 Engine Identication Decal
Engine Model Number:
Serial Number(s):
Gear Model Number:
Serial Number(s):
Boat Make:
Boat Model:
Hull Serial Number:
Propeller Size:
Ignition Key Number:
OWNER IDENTIFICATION AND REGISTRATION
INFORMATION
We suggest that you record the following information
for quick reference when ordering parts or requesting
service or warranty.
Model 5.7L CES - Tag is located on the inboard side of
the left hand rocker cover and the oil pan.
Model 5.7L CES Salt - Tag is located on the inboard
side of the left hand rocker cover and the oil pan.
Model 6.0L CES / 6.0L HO CES - Tag is located on the
intake manifold behind the throttle body and the oil pan.
Model 6.0L CES Salt / 6.0L HO CES Salt - Tag is
located on the heat exchanger and the oil pan.
Model 6.2L SC - Tag is located on the right hand side of
the supercharger cover and on the intercooler cooler.

14 L510032-16
ENGINE IDENTIFICATION - 3
CRUSADER CHALLENGER
ENGINE MODEL IDENTIFICATION / ADVISORY
MODEL 15 - 652VC - 01 SERIAL 765000
*SERIAL NUMBER I.D.*
1st DIGIT INDICATES DECADE ENGINE WAS
MANUFACTURED ( 7 = 2010 )
2nd DIGIT INDICATES CALENDAR YEAR ENGINE WAS
MANUFACTURED.
1st - 2nd Space: MANUFACTURING CODE
3rd - 5th Space: ENGINE CODE
575 = 5.7L
652 = 6.0L
653 = 6.0L HO
625 = 6.2L
6th - 7th Space: DRIVE CONFIGURATION
blank - Direct Drive
V- V-Drive
C- Catanium Clean Emissions System (CES)
S- Salt
8th - 9th Space: SPECIFICATION CODE

15
L510032-16
ELECTRONIC FUEL INJECTION INFORMATION - 4
ELECTRONIC FUEL INJECTION SYSTEM
The Challenger Engines covered in this manual are
equipped with an Electronic Fuel Injection (EFI) system,
which allows precise control of fuel and spark delivery.
The fuel system components of the EFI system are:
• The electric fuel pumps
• The throttle body assembly
• The fuel injectors
The fuel injection system is controlled by an Electronic
Control Module (ECM). The 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 an engine
overspeed protection, calibrated to a specic RPM, to
prevent engine damage from over-revving.
The sensors that the ECM monitors are:
• Engine Coolant Temperature (ECT) Sensor
• Throttle Position (TP) Sensor
• Manifold Absolute Pressure (MAP) Sensor
• Knock Sensor (KS) System
• Crankshaft Positioning (CKP) Sensor
• Camshaft Positioning (CMP) Sensor
• Intake Air Temperature (IAT) Sensor
• Throttle Control Position (TCP) Sensor
• Fuel Pressure (FP) Sensor, if equipped
Additional Sensors for CES ENGINES
• Pre-Catalyst Oxygen (O2) Sensors
• Post-Catalyst Oxygen (O2) Sensors
• Exhaust Manifold Water Temp (EMWT) Sensors
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
“MIL” Malfunction Indicator Lamp to alert the operator of
a malfunction.
In most cases, when the “MIL” is on, the engine(s) may
lose some performance and/or e󰀩ciency, but remain
running adequately. Also, the light may go out or
become intermittent, but a trouble code will be logged for
future diagnosis. (See Engine Alarm System - page 16)
In any case, the operator must obtain service by an
authorized Crusader Challenger Certied Dealer to
determine the exact cause of the malfunction.

16 L510032-16
OPERATING INSTRUCTIONS - 5
ENGINE ALARM SYSTEM (CES ENGINES)
The Crusader Challenger engine electronic system is
programmed to control the engine alarm system. Your
CES Engine Alarm System may utilize up to three (3)
alarm circuits to warn you of a potential problem with
your engine.
The alarm circuits have a “self” checking feature
programmed into the system. This feature will
momentarily illuminate the “lamps”, and if equipped,
sound the alarm for two short pulses upon initial start-up
of the engine.
The Malfunction Indicator Lamp (MIL) is used for
notication of any emissions-related fault. This is an
amber indicator lamp, that may be labeled ‘Service
Soon’ or with the ISO icon, to warn the operator of
possible engine problems.
The Check Gauges Lamp (CGL) is used for notication
of any non-emissions-related fault. This is a red
indicator lamp to warn the operator of possible
engine problems such as low oil pressure or an over
temperature condition.
The Buzzer is an audible notication to the operator, that
may be used in conjuction with the MIL and/or CGL.
For events such as an engine over-temperature
condition, low oil pressure, etc., the Buzzer will sound
for 1/2 second ON, 1/4 second OFF, continuously as an
audible warning. For emissions related faults (MIL), the
buzzer will initially sound for 5 seconds, then will sound
for 1/2 second ON once per minute thereafter. In the
event of a MIL circuit failure, MIL circuit functions will be
transferred to the Buzzer circuit.
The alarm circuit has a “self” checking feature
programmed into the system. This feature will light the
“MIL” and “CGL” lamps, and also sound the buzzer for
two short pulses upon initial start-up of the engine.
NOTE: If, during Key ON, engine OFF, either the MIL
or CGL lamps are ashing, this indicates that a stored
trouble code or engine fault is recorded in the ECM.
Refer to your Certied Dealer for proper diagnosis.
If the “MIL” or “CGL” lights and the alarm sounds during
operation, observe the instrument panel readings for
the possible source of the malfunction, such as low oil
pressure or excessive engine temperature readings.
Other conditions that may sound the warning buzzer are
a transmission over-temperature warning (if equipped),
exhaust manifold water over-temperature warning , and
for an electronic throttle malfunction.
IMPORTANT: A failure involving the Electronic Throttle
may result in Idle only operation of the engine. The
operator must obtain service by an authorized Crusader
Challenger Certied Dealer to determine the exact cause
of this malfunction as soon as possible.
In most cases, when the “MIL” or “CGL” lights are on, the
engine may lose some performance and/or e󰀩ciency,
but remain running adequately. Also, the lights may go
out or become intermittent, but a trouble code will be
logged for future diagnosis.
NOTE: If the MIL is blinking during Key ON, Engine OFF
situation, that means there is a stored diagnostic trouble
code.
In any case, the operator must obtain service by an
authorized Crusader Challenger dealer to determine the
exact cause of the malfunction.
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.