PleasureCraft Engine Group crusader Installation guide

OWNER’S OPERATION
and
MAINTENANCE MANUAL
A Division of

Welcome to the growing family of Crusader Marine Engines owners. We are delighted you have chosen Crusader
power for your boat and wish you many years of enjoyment.
READ THIS MANUAL THOROUGHLY
Before starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand
any portion of the manual, contact your Dealer for clarification or assistance. Ask your Dealer for a demonstration of
actual starting and operating procedures.
The descriptions and specifications contained in this manual were in effect at the time of printing. Crusader Marine
Engines’ policy of continued improvement reserves the right to change specifications or design without notice and
without obligation.
This manual will cover the following Crusader engines:
Year Model
2005 5.0L MPI
2005 5.7L MPI
2005 6.0L MPI
2005 8.1L MPI
2005 8.1L MPI (HO)
Part Number - L510001-05 Printed 12/04

1
L510001-05
SERVICE AND WARRANTY .................................................................................................... 4-19
Safety Information ...................................................................................................................... 4
Replacement Parts ........................................................................................................................... 4
Safety Warnings ......................................................................................................................... 4
Crusader Marine Engines’ Commitment to You ................................................................................. 5
Owner Warranty Registration (Warranty Registration Card is located at the back of this manual) ................ 5
Engine Operation and Care .......................................................................................................... 6
Maintenance Records ................................................................................................................. 6
Local Repair Service ................................................................................................................... 6
Service Away From Home ............................................................................................................ 6
Replacement Parts Inquiries ......................................................................................................... 7
Replacement Service Parts .......................................................................................................... 7
Applicable Limited Warranty ......................................................................................................... 7
Crusader Marine Engines One-Year Limited Warranty
(For Engines Sold and Used in the United States and Canada) ........................................................... 8
Items Not Covered Under the Limited Warranty ............................................................................... 10
Things You Should Know About The Warranty ................................................................................ 11
California Emission Control Warranty Statement ............................................................................. 12
Crusader, Inc. Model Years 2003-2008 General Emissions Warranty Coverage ..................................... 13
Marine Transmissions ................................................................................................................ 15
Captain’s Choice Series Engines ................................................................................................. 15
Resolving a Service Problem ...................................................................................................... 16
Dealer’s Responsibilities ............................................................................................................ 17
Transferable Warranty ................................................................................................................ 18
Direct Sale By Owner ................................................................................................................ 18
Notes ..................................................................................................................................... 19
BOATING RESPONSIBILITY ................................................................................................. 20-22
Carbon Monoxide Hazard ........................................................................................................... 20
Safe Boating Suggestions .......................................................................................................... 21
Water Wisdom .......................................................................................................................... 21
Operation and Maintenance ........................................................................................................ 21
Rules of the Road ..................................................................................................................... 22
ENGINE IDENTIFICATION .................................................................................................... 23-24
Engine Identification .................................................................................................................. 23
Owner Identification and Registration Information ............................................................................ 23
2005 Model Identification / Advisory ............................................................................................. 24
ELECTRONIC FUEL INJECTION INFORMATION ..................................................................... 25-27
Electronic Fuel Injection System .................................................................................................. 25
Power Reduction Mode .............................................................................................................. 26
High Engine Coolant Temperature ................................................................................................ 26
Low Engine Oil Pressure ............................................................................................................ 27
TABLE OF CONTENTS

2L510001-05
TABLE OF CONTENTS
High Transmission Fluid Temperature ............................................................................................ 27
OPERATING INSTRUCTIONS ................................................................................................ 28-32
Engine Alarm System ................................................................................................................ 28
Instrumentation ........................................................................................................................ 28
Remote Controls ...................................................................................................................... 29
Starting Engine (Fuel Injected Engines) ........................................................................................ 30
Shifting Transmission ................................................................................................................. 31
Stopping Engine ....................................................................................................................... 32
Freezing Temperature Operation .................................................................................................. 32
Operation in High Debris Areas ................................................................................................... 32
CONDITIONS AFFECTING OPERATION ................................................................................. 33-34
Trim and Weight Distribution ........................................................................................................ 33
Boat Bottom ............................................................................................................................. 33
Propeller Selection .................................................................................................................... 34
ENGINE BREAK-IN PERIOD ..................................................................................................... 35
25-HOUR ENGINE INSPECTION ................................................................................................ 36
FUEL REQUIREMENTS ............................................................................................................ 37
Gasoline Requirements .............................................................................................................. 37
Gasoline Containing Alcohol ....................................................................................................... 37
OIL REQUIREMENTS ............................................................................................................... 38
Engine Oil Recommendations ..................................................................................................... 38
Transmission and “V”-Drive Oil Requirements ................................................................................. 38
ENGINE MAINTENANCE ...................................................................................................... 39-68
Engine Maintenance .................................................................................................................. 39
Checking Fluid Levels ........................................................................................................... 39-40
Lubrication .............................................................................................................................. 41
Electrical System Circuit Breaker(s) .............................................................................................. 42
Electrical System Fuses ............................................................................................................. 42
Ignition Fuse ............................................................................................................................ 42
Electrical System Wiring and Connectors ...................................................................................... 42
Battery .................................................................................................................................... 43
Fresh Water Cooling System Sacrificial Zinc Anode ......................................................................... 44
Checking Coolant Level ............................................................................................................. 45
Flushing Cooling System - Sea-Water Section ................................................................................ 46
Testing Coolant For Alkalinity ...................................................................................................... 47
Draining Fresh-Water Cooling System .......................................................................................... 47
Filling Fresh-Water Cooling System .............................................................................................. 48
Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) ....................... 49
Fuel System Description ............................................................................................................ 50
Fuel Control Cell (FCC) Fuel System ............................................................................................ 50
Servicing the FCC ..................................................................................................................... 51
FCC Service Instructions (Screw-On Canister) ............................................................................... 52

3
L510001-05
TABLE OF CONTENTS
FCC Service Instructions (Clamp-On Canister) ............................................................................... 53
Primary Fuel Filter .................................................................................................................... 54
Water Separating Fuel Filter ....................................................................................................... 55
Priming Fuel System ................................................................................................................. 55
Flame Arrestor ......................................................................................................................... 55
Accessory Drive Belt ............................................................................................................. 56-58
Changing Oils .......................................................................................................................... 59
Engine Alignment ................................................................................................................. 60-62
Engine Maintenance Log ............................................................................................................ 63
Maintenance Schedule .......................................................................................................... 64-65
Visual Inspection ...................................................................................................................... 66
Engine Fluid Capacities ............................................................................................................. 66
Transmission Fluid Capacities ..................................................................................................... 66
Filter Requirements ................................................................................................................... 67
On-Board Parts Kits .............................................................................................................. 67-69
ENGINE SPECIFICATIONS ................................................................................................... 70-72
OUT-OF-SEASON STORAGE ................................................................................................ 73-76
Engine Storage ........................................................................................................................ 73
Draining Instructions .................................................................................................................. 74
Battery Storage ........................................................................................................................ 74
Out-Of-Season Engine Warm-Up ................................................................................................. 75
Recommissioning After Storage .............................................................................................. 75-76
TROUBLESHOOTING .......................................................................................................... 77-79
WATER FLOW DIAGRAMS ................................................................................................... 80-83
INSTRUMENTATION WIRING DIAGRAM ..................................................................................... 84
LITERATURE .......................................................................................................................... 85
FORMS .............................................................................................................................. 87-91
CRUSADER OWNERSHIP CHANGE NOTICE .............................................................................. 87
CRUSADER WARRANTY TRANSFER APPLICATION (PORT OR SINGLE ENGINE) ........................... 89
CRUSADER WARRANTY TRANSFER APPLICATION (STARBOARD ENGINE) .................................. 91
NOTES ................................................................................................................................... 93

4L510001-05
SERVICE and WARRANTY - 1
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 Crusader Marine 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.
WARRANTY NOTICE: Indicates a possible warranty exclusion.
IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily.

5
L510001-05
SERVICE and WARRANTY - 1
OWNER’S SERVICE
AND
WARRANTY INFORMATION
CRUSADER MARINE ENGINES’ COMMITMENT TO YOU
Crusader Marine Engines is committed to assuring your satisfaction with your new Crusader engine. Your Dealer
also wants you to be completely satisfied, and invites you to return for all your servicing needs, both during and after
the warranty period.
OWNER WARRANTY REGISTRATION
It is important that your selling dealer fill out the “Warranty Registration Card” completely and mail it to the factory
immediately upon the purchase of the new product. It identifies the name and address of the original purchaser, product
model(s) and serial number(s), and the selling dealer’s name and address. The dealer is also certifying that you are
the original purchaser of the product.
Upon receipt of the “Warranty Registration Card” at the factory, you will be issued an “Owner Warranty Registration
Card.” The “Owner Registration Card” is your only valid registration identification, and must be presented to the
servicing dealer, should warranty service be required.
If your “Owner Registration Card” is not received within 30 days from the date of purchase, please contact your boat
dealer or engine seller. The product warranty is not effective until the Product is registered at the factory.
Mail registration information to:
NOTE: OWNERS WARRANTY REGISTRATION CARD IS LOCATED AT THE BACK OF THIS MANUAL.
NOTICE: Registration lists must be maintained by the factory and dealer on marine products sold in
the United States and some foreign countries, should notification under FEDERAL BOAT SAFETY
ACT be required. It is our desire to have all products registered at the factory, should it ever be
necessary to contact you. Make sure your Dealer/Distributor fills out the registration card immediately
and sends the card to the factory.
Crusader Marine Engines
P.O. Box 369
Little Mountain, SC 29075

6L510001-05
SERVICE and WARRANTY - 1
ENGINE OPERATION AND CARE
Considering the investment that you have made in your new Crusader engine(s), we know you will want to operate
and maintain it properly. We urge you to follow the maintenance instructions contained in your engine’s “Operation
and Maintenance Manual.”
If you have any questions on how to keep your engine in good working condition, see your selling dealer, the place
where many owners choose to have their maintenance work done. Your dealer can be relied on to use proper parts
and practices.
MAINTENANCE RECORDS
It is recommended that receipts covering the performance of regular maintenance be retained. Damage to your engine,
caused by lack of maintenance, is not covered under your warranty. Receipts can be very important if a question arises
as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship. An “Engine
Maintenance Log” is provided in the MAINTENANCE SCHEDULE section of the OPERATION AND MAINTENANCE
MANUAL for your convenience in recording the service performed.
LOCAL REPAIR SERVICE
To obtain service or make a claim under your warranty, contact your selling dealer. They have trained technicians,
knowledge and special tools and equipment to properly service your engine, if the need arises. They know you and
your boat the best.
SERVICE AWAY FROM HOME
If you are away from home and your local dealer, and the need for service arises, contact the Crusader Captain’s Club™
Concierge using your exclusive Captain’s Club toll-free number. The Club Concierge is there to support your local
dealer or locate the closest Crusader authorized technician. She can personally expedite parts orders so that in most
cases, shipment is made within 24 hours, delivered on time to the location you specify.

7
L510001-05
SERVICE and WARRANTY - 1
REPLACEMENT PART INQUIRIES
All inquiries concerning replacement parts should be directed to your local authorized dealer. The dealer has the
necessary information to order parts for you if they are not in stock. Only authorized distributors can purchase parts
from the factory. Crusader Marine Engines does not sell to unauthorized dealers or retail customers. When checking on
parts, the dealer will require the engine model and serial number to order the correct parts.
REPLACEMENT SERVICE PARTS
WARNING
Electrical, ignition and fuel system components on Crusader engines are designed and manufactured to comply with
U.S. Coast Guard rules and regulations to minimize the risks of fire or explosion. Use of replacement electrical,
ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire or
explosion hazard and should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important that all the components are properly
installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors
from fuel system leaks, if they existed.
APPLICABLE LIMITED WARRANTY
Following is the limited warranty applicable to Crusader Marine Engines sold and used in the United States and
Canada.
Distributors and Dealers are not agents of Crusader. Crusader does not authorize any person to create any other
obligation or liability in connection with this product.

8L510001-05
SERVICE and WARRANTY - 1
CRUSADER, INC. INBOARD MARINE ENGINES
ONE YEAR LIMITED WARRANTY
(For Engines Sold and Used in the United States and Canada Only)
1. Crusader, Inc. (hereinafter referred to as “Crusader”) warrants each of its new inboard marine engines and
accessories attached thereto (“Products”), to be free from defects in material and workmanship for a period of
one (1) year, except to the extent limited herein. This Limited Warranty commences on the day of the first retail
sale and/or the first date used, and extends to the original and subsequent retail sales; however, in no event shall
the duration of the Limited Warranty exceed one (1) year, as measured from the original retail sale date.
2. Under this Limited Warranty, Crusader’s obligation is limited to repairing or replacing those parts of Products that
have become defective within the applicable warranty period, because of defective materials or workmanship.
Crusader will arrange for the correction of all defects under this Limited Warranty to be made free of charge
at the selling dealership or an authorized Crusader service center. Crusader, in its discretion, may provide for
the repair or replacement of any defective part at Crusader’s facility. Crusader will make payment for labor to
replace such parts as provided in the, then, current flat rate labor manual or Warranty Procedures Manual.
3. This Limited Warranty does not apply to Product defects caused by normal wear and tear to Products, and/or
damage to Products arising out of negligence or lack of proper care, improper installation or service, operation
with fuels, oils or lubricants which are not suitable for use with Products, alterations or removal of parts,
water entering an engine through the exhaust system or carburetor, installation of accessories or parts not
manufactured or sold by Crusader, or Products rendered defective by accident.
4. If a part should become defective within the applicable warranty period, advance authorization by Crusader is
necessary before the part is replaced or a defect is corrected by a service representative; otherwise Crusader will
not be liable for the expense of the replacement or correction.
5. Replacement parts and accessories supplied by Crusader, and installed on a Product during the period when
the Product is covered under the provisions of this Limited Warranty, are warranted for the unexpired portion of
the existing warranty period, or ninety (90) days from the date of installation of such new parts or accessories,
whichever is longer.
6. Reasonable access to the Product must be provided for warranty service. This Limited Warranty does not
cover: (1) telephone or telegram charges, towing charges, storage, launch and haul out charges, loss or damage
to personal property, loss of revenue, loss of time, travel, lodging, inconveniences or other CONSEQUENTIAL
DAMAGES, or (2) removal and/or replacement of boat partitions or material, because of boat design, for
necessary access to the Product.