PCM 2003 5.0L MPI Installation guide

OWNER’S OPERATION
and
MAINTENANCE MANUAL
A Division of

Part Number - L510010-03 Printed 3/03
Thank you for your selection of Pleasurecraft (PCM) Marine Power for your boating needs. We welcome you to Team
PCM, 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 20 years.
When you chose PCM, you selected the utmost in premium power for your boating application. Pleasurecraft is the
world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting edge technology. Over the
years, we have introduced many breakthrough innovations that quickly became industry standards. The pyramidal exhaust
system, light-weight transmission, computerized engine control and the Fuel Control Cell (FCC) are all PCM innovations.
No matter which PCM model you purchased, you can be sure it is equipped with the latest in modern technology for
added performance and durability.
READ THIS MANUAL 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 demostration of actual
starting and operating procedures.
The descriptions and specifications contained in this manual were in effect at the time of printing. PCM Engines’ policy of
continued improvement reserves the right to change specifications or design without notice and without obligation.
This manual will cover the following PCM engines:
Year Model
2003 5.0L MPI
2003 5.7L MPI
2003 6.0L MPI
2003 8.1L MPI (HO)

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INTRODUCTION ..................................................................................................................... 3-5
Registration Information (Warranty Registration Card is located at the back of this manual) ....................... 3
3-Year Transferable Limited Warranty ..............................................................................................4
California Emission Control Warranty Statement ............................................................................... 5
PCM Model Years 2003-2008 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 Identification .................................................................................................................. 13
Owner Identification and Registration Information ............................................................................ 13
2003 Model Identification / Advisory ............................................................................................. 14
ELECTRONIC FUEL INJECTION INFORMATION .......................................................................... 15
Electronic Fuel Injection System .................................................................................................. 15
Power Reduction Mode .............................................................................................................. 15
OPERATING INSTRUCTIONS ................................................................................................ 16-20
Engine Alarm System ................................................................................................................ 16
Instrumentation ........................................................................................................................ 17
Starting Engine (Fuel Injected Engines) ........................................................................................ 18
Shifting Transmission ................................................................................................................. 19
Stopping Engine ....................................................................................................................... 20
Freezing Temperature Operation .................................................................................................. 20
Operation in High Debris Areas ................................................................................................... 20
CONDITIONS AFFECTING OPERATION ................................................................................. 21-22
Trim and Weight Distribution ........................................................................................................ 21
Boat Bottom ............................................................................................................................. 21
Propeller Selection .................................................................................................................... 22
ENGINE BREAK-IN PERIOD ..................................................................................................... 23
25-HOUR ENGINE INSPECTION ................................................................................................ 24
FUEL REQUIREMENTS ............................................................................................................ 25
Gasoline Requirements .............................................................................................................. 25
Gasoline Containing Alcohol ....................................................................................................... 25
OIL REQUIREMENTS ............................................................................................................... 26
Engine Oil Recommendations ..................................................................................................... 26
Transmission and “V”-Drive Oil Requirements ................................................................................. 26
ENGINE MAINTENANCE ...................................................................................................... 27-55
Engine Maintenance .................................................................................................................. 27
TABLE OF CONTENTS

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Checking Fluid Levels ........................................................................................................... 27-28
Lubrication .............................................................................................................................. 29
Electrical System Circuit Breaker(s) .............................................................................................. 30
Electrical System Fuses ............................................................................................................. 30
Ignition Fuse ............................................................................................................................ 30
Electrical System Wiring and Connectors ...................................................................................... 30
Battery .................................................................................................................................... 31
Fresh Water Cooling System Sacrificial Zinc Anode ......................................................................... 32
Checking Coolant Level ............................................................................................................. 33
Flushing Cooling System - Sea-Water Section ................................................................................ 34
Testing Coolant ForAlkalinity ...................................................................................................... 35
Draining Fresh-Water Cooling System .......................................................................................... 35
Filling Fresh-Water Cooling System .............................................................................................. 36
Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) ....................... 37
Fuel System Description ............................................................................................................ 38
Fuel Control Cell (FCC) Fuel System ............................................................................................ 38
Servicing the FCC ..................................................................................................................... 39
Draining the FCC Bowl, ENGINE OFF .......................................................................................... 40
Filter Element Replacement, ENGINE OFF .................................................................................... 40
Primary Fuel Filter .................................................................................................................... 41
Priming Fuel System ................................................................................................................. 42
Flame Arrestor ......................................................................................................................... 42
Accessory Drive Belt ............................................................................................................. 43-46
Changing Oils .......................................................................................................................... 47
Engine Alignment ................................................................................................................. 47-50
Engine Maintenance Log ............................................................................................................ 51
Maintenance Schedule .............................................................................................................. 52
Visual Inspection ...................................................................................................................... 54
Engine Fluid Capacities ............................................................................................................. 54
Transmission Fluid Capacities ..................................................................................................... 54
Filter Requirements ................................................................................................................... 55
ENGINE SPECIFICATIONS ................................................................................................... 56-57
OUT-OF-SEASON STORAGE ................................................................................................ 58-61
Engine Storage ........................................................................................................................ 58
Draining Instructions .................................................................................................................. 59
Battery Storage ........................................................................................................................ 60
Fitting Out After Storage ............................................................................................................. 61
TROUBLESHOOTING .......................................................................................................... 62-65
WATER FLOW DIAGRAMS ................................................................................................... 66-70
INSTRUMENTATION WIRING DIAGRAM ..................................................................................... 71
LITERATURE .......................................................................................................................... 72
FORMS............................................................................................................................... 73-76
NOTES ............................................................................................................................... 77-79
TABLE OF CONTENTS

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REGISTRATION INFORMATION
(Warranty Registration Card is located at the
back of this manual)
Shortly after your purchase is registered with PCM, you
will be mailed your Warranty Card and a Customer
Survey. We appreciate your feedback and encourage
you to fill 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 website at www. pleasurecraft.com.
Again, thanks for choosing PCM. We sincerely wish you
happy days on the water.
INTRODUCTION - 1

INTRODUCTION - 1
3 Year Transferable Limited Warranty
Pleasurecraft Marine Engine Co. (PCM) warrants its new products to be free from defects in material and workmanship under normal use and service conditions, to the first
registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty coverage within 30 days of any subsequent
sale/purchases. All components of PCM products are covered under the PCM Warranty, except for those components that are warranted by PCM’s suppliers. The obligation of PCM hereunder
shall be limited to the repair or replacement with new or remanufactured components, at its option, of any product or parts thereof which has failed during the period of warranty and which is
demonstrated upon examination to have failed due to defective material and/or workmanship.
PCM’s policy is one of continued improvement of its products and PCM 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.
NO OTHER WARRANTY GIVEN
The obligations set forth in the preceding paragraph are PCM’s sole obligation and owner’s exclusive remedy. PCM makes no other express warranty to the extent
that any additional warranty may be implied by law, the term of such implied warranty shall be limited to the warranty term stated herein, from the date of delivery of the
PCM product to the parties outlined herein.
No distributor, dealer, agent or employee of PCM is authorized to grant any other or further warranty or incur any additional warranty obligation on PCM’s behalf, in connection with
the sale of its products. Any qualification or restriction contained herein which is prohibited by any law of mandatory application shall be deemed to be deleted herefrom, however, such deletion
shall have no effect on the remaining provisions hereof, all of which shall remaining full force and effect.
REMEDIES
The obligations of PCM set forth in the first 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 which are made by PCM is repair or replacement of the product or any warranted part thereof as set forth herein: with this sole exception,
PCM 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 profits,
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 modification of any boat parts to facilitate repairs, moving of furniture, carpets, cleaning, painting,
carpenter work, or re-delivery charges.
Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.
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 PCM’s liability exceed the purchase price of the goods which is actually paid to PCM.
WARRANTY COVERAGE, TERM
This Warranty is extended only to the first registered owner or registered user, and all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any
remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases, for the period specified below:
All components, other than and those itemized below, are warranted for a period of three (3) years from the date of delivery to the first registered owner or registered user, and
all subsequent user who, in accordance with PCM’s warranty transfer policy, transfers any remaining portion of this warranty coverage within 30 days of any subsequent sale/purchases in
non-commercial use. In case of commercial use, the term of this Warranty shall be the shorter of (a) a period of six (6) months from the date of delivery to the first registered owner or
registered user or (b) the expiration of 200 hours of use.
Items not covered under this warranty;
(A) Water pump impellers are not covered by this Warranty.
(B) Seals, gaskets, O-rings, and other material affected by time are not covered by this Warranty if their effectiveness is reduced by an extended storage period prior to
sale or use.
(C) Components supplied by the Ford Motor Co. are warranted by the Industrial Engine Division of the Ford Motor Co. and are not covered by this Warranty.
OBTAINING PERFORMANCE UNDER WARRANTY
PCM’s warranty registration form should be prepared by your selling dealer, executed by you and the dealer and mailed, by you, to PCM within 30 days after the date of purchase.
Upon receipt of the warranty registration form, PCM 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 eight (8) weeks after the date of purchase, please write PCM at the address 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 PCM dealers
or distributors are entitled to be reimbursed by PCM for some or all of the expense of warranty repairs, thus, service under the terms of this Warranty will be performed by an authorized
PCM dealer or distributor without charge for established flat rate labor or replacement parts, other than items not covered by the Warranty, such as , but not limited to, lubricants, spark plugs,
points, 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 flat rate must be paid for by the owner.
Prior authorization in writing must be obtained from PCM 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 PCM. While failure to present the owner’s registration card will not prevent you from
obtaining coverage hereunder, this Warranty shall not be effective and, therefore, cannot be honored until the product purchase date can be confirmed by PCM. If the card is lost, communicate
with PCM 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
FAILURES EXCLUDED FROM WARRANTY
This Warranty will not apply to any failure which results from accidents, sinking, fire, neglect, abuse, or abnormal service or use, such as racing, towing or operation in water
of insufficient 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 PCM. This Warranty does not apply to any engine or drive which has been modified,
or altered, or repaired in such a manner as, in the opinion of PCM, to affect its stability, reliability or performance. Further, this Warranty will not apply to failure resulting from use of
non-recommended lubricants or fuels, failure to follow maintenance or lubrication schedules, failure caused or contributed to by contaminated fuel, failure caused by improper installation
or misapplication of the engine or drive, failure resulting from the owner’s or operator’s failure to exercise due or normal care and precaution, or failure of components and/or assemblies
that are warranted by PCM suppliers.
OWNER’S RESPONSIBILITY
Performance under this Warranty shall be conditioned upon the first registered owner’s or registered users’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 PCM after accepting delivery.
3 Owner or user shall follow the instruction 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 laws of the State of Ohio, except only to the extent replaced or 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 PCM California Model Years 2003-2008 Emissions Warranty and California Emissions Control Warranty Statement is a separate document included in this Manual. Any
questions concerning the Emissions Warranty can be obtained by calling 1-803-345-0050.

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CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Pleasurecraft Marine Engine Co. (hereinafter “Pleasurecraft”) 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. Pleasurecraft 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, Pleasurecraft 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. Pleasurecraft recommends that you retain all receipts covering maintenance on your
inboard engine, but Pleasurecraft 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 Pleasurecraft may deny you warranty cover-
age 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 Pleasurecraft 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 Pleasurecraft
at 1-803-345-0050.
INTRODUCTION - 1

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PLEASURECRAFT MARINE ENGINE CO. MODEL YEARS 2003-2008 GENERAL
EMISSIONS WARRANTY COVERAGE
1. Pleasurecraft Marine Engine Co. (hereinafter referred to as “Pleasurecraft”) warrants to the first owner
purchasing at retail, and all subsequent owners, of every Pleasurecraft Model Years 2003-2008 inboard engine
that the emissions control devices on Pleasurecraft 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 4.7§ 2445.1, Pleasurecraft
warrants that each Pleasurecraft engine is designed, built and equipped to conform with all applicable regula-
tions adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Divi-
sion 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 Pleasurecraft’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 Pleasurecraft Owners/Operators Manual, is warranted for the
period of two (2) years. If the part fails during the period of warranty coverage, Pleasurecraft will repair or
replace the defective part at any Pleasurecraft 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.
4. Any part covered under this Warranty that is scheduled only for regular inspection in the written instruc-
tions to be found within the Pleasurecraft Owners/Operators Manual, is warranted for the period of two (2)
years. If the part fails during the period of warranty coverage, Pleasurecraft will repair or replace the defec-
tive part at any Pleasurecraft 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 Pleasurecraft 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 sched-
uled replacement, Pleasurecraft will repair or replace the defective part at any Pleasurecraft 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 Pleasurecraft supplied part, will not shorten nor
extend the warranty period(s) stated in paragraphs one (1) thru four (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 Pleasurecraft
warranty station.
INTRODUCTION - 1

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INTRODUCTION - 1
8. To insure prompt repair under this Warranty, Pleasurecraft 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 Pleasurecraft without charge to the owner.
9. 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, and mounting hardware, pulleys,
belts and idlers, temperature check, and valves and switches, and electronic controls.
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 Pleasurecraft 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. Pleasurecraft 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
Pleasurecraft may not meet this requirement and will be grounds for disallowing a claim made under this War-
ranty. Pleasurecraft will not be liable under this Warranty or provide warranty coverage for product failures
caused by parts other than Pleasurecraft original equipment parts.
12. If you have any questions regarding your warranty rights and responsibilities, or the location of
Pleasurecraft warranty stations near you, you should contact Pleasurecraft at 1-803-345-0050.

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Intentionally
Left Blank
INTRODUCTION - 1

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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 fire or
explosion hazard and should be avoided.
Always request that genuine PCM Engines replacement
parts be used in any repairs or maintenance being
performed on your engine(s).
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 fire 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.
IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily.
WARRANTY NOTICE: Indicates a possible warranty exclusion.
INTRODUCTION - 1

10 L510010-03
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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 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.
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 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 Randolph 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 & Yacht Council, Inc.
3069 Solomon’s Island Road
Edgewater, MD 21037-1416
www.abyc.com
410-956-1050

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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
offered 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
PCM 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.
• 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 “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.
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
• PCM 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
• 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 PCM engine. When service and maintenance are
required, return to your authorized PCM Engine Dealer.

12 L510010-03
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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
flashing red light. It indicates 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
from sea. The quick flashing light indicates
special caution required.
BOATING RESPONSIBILITIES - 2
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
• 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
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. Ventilate all components for a minimum of five
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
L510010-03
C.C.
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.
Figure 3-2 Engine Identification Tag Locations (5.0/5.7L)
MAKE
MODEL SERIAL
FIRING ORDER
THIS ENGINE CONFORMS TO ALL APPLICABLE U.S.
GOVERNMENT STANDARDS FOR MARINE ENGINES
IN EFFECT AT DATE OF MANUFACTURE.
LITTLE MOUNTAIN, SC 29075
Figure 3-1 Engine Identification Decal
PORT STARBOARD
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.
MAKE
MODEL SERIAL
FIRING ORDER
THIS ENGINE CONFORMS TO ALL APPLICABLE U.S.
GOVERNMENT STANDARDS FOR MARINE ENGINES
IN EFFECT AT DATE OF MANUFACTURE.
LITTLE MOUNTAIN, SC 29075
1. ENGINE SPECIFICATION DECAL
2. ENGINE IDENTIFICATION DECAL
3. TRANSMISSION
IDENTIFICATION PLATE
3
2
2
1
OIL TYPE:
DEXRON III
HIGHWAY 76 EAST
LITTLE MOUNTAIN
S.C. 29075
SERIAL No
MODEL
MARINE POWER
RATIO
CHECK OIL LEVEL DAILY
OIL CHANGE AFTER FIRST 25 HOURS OF
OPERATION AND EVERY 100 HOURS OR 12
MONTHS, WHICHEVER OCCURS FIRST.
IMPORTANT NOTE: WARRANTY IS VOID IF
MAINTENANCE AND LUBRICATION INSTRUCTIONS
PER PCM MANUAL ARE NOT FOLLOWED.
PCM
marine engines
ENGINES
Important! See yours owners manual to insure that specifications for your
engine have not changed or been ommitted from the specifications listed.
FUEL RECOMMENDATIONS
Unleaded 89 Octane (Minimum)
FUEL PRESSURE
48-52 @ Idle
53-57 @ W.O.T.
ENGINE OIL RECOMMENDATIONS
15W-40 Above 50 degrees F
5W-30 Below 50 degrees F
MARINE GEAR OIL RECOMMENDATIONS
All PCM, Warner and Hurth Transmissions: Dextron III
MAXIMUM CONTINUOUS CRUISE: 3800 RPM
MAXIMUM ENGINE SPEED (WOT): 5000 RPM
ELECTRICAL SPECIFICATIONS
12 Volts - Negative Ground
SPARK PLUG: Gap .060"
FIRING ORDER: 18436572
IGNITION TIMING @ 1000 RPM
10 degrees (Non-adjustable)
ENGINE IDLE: 650-700 (Non-adjustable)
5.7L 350 c.i.d MULTIPORT FUEL INJECTION

14 L510010-03
C.C.
ENGINE IDENTIFICATION - 3
PCM
2003 MODEL IDENTIFICATION / ADVISORY
MODEL P X L A P R R 123 M SERIAL 430000
8th 9th 10th Spaces: DRIVE GEAR RATIO OR REDUCTION
The drive gear ratio will appear in these spaces
which identifies the production gear specs. The
example gear number shown is a (1.23:1). If
the gear being identified does not have 3 digits,
a “0” will appear in 10th space.
Example: ( 1.0:1 ) will appear as 100
( 1.5:1 ) will appear as 150
*MODELS ENDING WITH “000000” IN
PLACE OF DRIVE I.D. ARE BOBTAIL ENGINES.
11th Space: IGNITION / FUEL TYPE USED
D- DISTRIBUTOR (Carb)
E- THROTTLE BODY INJECTION
M- MULTI-PORT FUEL INJECTION
*SERIAL NUMBER I.D.*
1st DIGIT INDICATES DECADE ENGINE WAS
MANUFACTURED ( 3 = 1990, 4 = 2000, 5 = 2010 )
2nd DIGIT INDICATES YEAR ENGINE WAS
MANUFACTURED.
1st Space: MANUFACTURER
P- Pleasurecraft Marine
2nd Space: FACTORY FRESHWATER / CLOSED COOLING
X-Freshwater Cooled
(Space Omitted If Raw Water Cooled )
3rd Space: ENGINE ROTATION
L- Rotation, Left-Hand from Rear
R- Rotation, Right-Hand from Rear
4th Space: ENGINE TYPE
A= 5.7L (350 CID HO) (GM)
Q= 6.0L (364 CID) (GM)
G= 5.0L (305 CID STD) (GM)
X= 8.1L (496 CID STD) (GM)
Z= 8.1L (496 CID HO) (GM)
5th Space: DRIVE MANUFACTURER
P- Pleasurecraft
W- Borg-Warner
V- Velvet Drive (cast iron units. Specify 71c or
72c)
H- Hurth
6th Space: DRIVE FUNCTION / APPLICATION
R- Reverse / Reduction
V- Vee Drive / Reversed Risers
F- Full Reversing
7th Space: PROPELLER SHAFT ROTATION
L- Left-Hand Rotation
R- Right-Hand Rotation

15
L510010-03
C.C.
ELECTRONIC FUEL INJECTION INFORMATION - 4
ELECTRONIC FUEL INJECTION SYSTEM
The PCM 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 pump
• 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 specific
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
POWER REDUCTION MODE
The ECM monitors engine oil pressure and engine
coolant temperature whenever the engine is running.
If either 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 protect the engine 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.
NOTICE: If it is not possible to safely shut off the engine,
return the engine to idle speed. Once returned to idle,
the ECM will allow the engine to operate normally below
2000 RPM.

16 L510010-03
C.C.
ENGINE ALARM SYSTEM (IF EQUIPPED)
The PCM 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 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. The engine should be shut off to
prevent damage to the engine.
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.
OPERATING INSTRUCTIONS - 5

17
L510010-03
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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
OPERATING INSTRUCTIONS - 5