MARINE ILLUSTRATED PARTS MANUAL

Transcription

1 MARINE ILLUSTRATED PARTS MANUAL MODEL MP 6.0L SN thru 48xxxx L /08

2 This Page Was Intentially Left Blank

3 MODEL MP6.0L PARTS MANUAL - Contents: Symbols... Maintenance Item Part Numbers... Cylinder Block Assembly - Figure... 4 Cylinder Head Assembly / Front Cover - Figure... 6 Exhaust Manifold Assembly / Knock Sensors - Figure... 0 Intake Manifold Components - Figure 4... Oil Pan and Oil Pump Assembly - Figure... 4 Throttle Body Assemblies and Related Components - Figure Remote Oil Filter Components (Standard Drive) - Figure Remote Oil Filter Components ( V - Drive) - Figure Fuel Control Cell (FCC) Components - Figure 9... Heat Exchanger and Components - Figure Fresh Water Cooling System Components - Figure... 6 Raw Water Drain System Components - Figure... 8 Exhaust Manifold and Components - Figure... 0 Exhaust Manifold 4 Spacer Kit and Components - Figure 4... Raw Water Cooling Pump - Figure... 4 Wiring Harness Assemblies and Senders - Figure ECM and Relays - Figure Accessory Drive System Components - Figure Starter Assembly Components - Figure Engine and Transmission Mounts - Figure Bellhousing Assembly - Figure Transmission and Related Parts (Standard Drive) - Figure Transmission and Related Parts ( V - Drive) - Figure... 0 ENGINE ROTATION TYPICAL VIEWS ARE SHOWN Engine Rotation is identifi ed as RH or LH with the engine model number. Rotation always is determined from the fl ywheel end looking toward the front of the engine. In some instances, propeller shaft rotation may be opposite to that of the engine. When ordering a replacement engine, production block or parts for the engine, be certain to check engine rotation. DO NOT rely on propeller rotation in order to determine engine rotation. LEFT-HAND ROTATION is STANDARD ROTATION. (Flywheel turns counterclockwise when viewed from fl ywheel end of the engine.) RIGHT-HAND ROTATION is OPPOSITE ROTATION. (Flywheel turns clockwise when viewed from fl ywheel end of the engine.) L PCM ZR409

4 MODEL MP6.0L PARTS MANUAL - HOW TO READ THIS PARTS BOOK: ITEM PART NO. QTY. DESCRIPTION MODEL ID RB0000I Base Engine Assembly, 6.0L 4 4 ITEM NUMBER - This number corresponds with the number in the exploded view on the facing page. PART NUMBER - This is the designated part number for the particular component or assembly. QUANTITY - This refers to the number of pieces used. DESCRIPTION - This identifi es what the component or assembly is. MODEL ID - This identifi es a component or assembly that is unique to a specifi c engine model. ====================================================================== Symbols shown throughout parts list are defi ned here or on the bottom of the individual parts list page. AR = As Required OPT = Optional NSS = Not Serviced Separately NA = Not Available OS = Oversize US = Undersize TBD = To Be Determined NI = Not Illustrated ====================================================================== PCM ZR409 L007-08

5 MODEL MP6.0L PARTS MANUAL - REPLACEMENT PARTS: WARNING: Electrical, ignition and fuel system components on PCM Engines are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize risks of fi re or explosion. Use of replacement electrical, ignition and fuel system components which do not comply with these rules and regulations could result in a fi re or explosion hazard and should be avoided. MAINTENANCE ITEM PART NUMBERS: Description Oil Filter Kit, Transmission Oil Filter (ZF) Fuel Filter, Primary Fuel Filter (FCC) Spark Plugs Spark Plug Wire Set Serpentine Drive Belt Raw Water Pump Impeller Kit Thermostat Part Number R07700 RP0770 R08004A RP08006 RP000 RK00 R0660 RP060 R0600 MARINE TRANSMISSIONS: PCM Engines are equipped with PCM or Hurth Transmissions, standard or V -drive. If transmission parts are required, contact your dealer or closest PCM Parts Distributor for required parts. Parts manuals and overhaul manuals are available through PCM Distributors. L PCM ZR409

6 MODEL MP6.0L PARTS MANUAL - 4 CYLINDER BLOCK ASSEMBLY - FIGURE PCM ZR409 L007-08

7 MODEL MP6.0L PARTS MANUAL - CYLINDER BLOCK ASSEMBLY - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID * TBD Base Engine Assembly TBD Bearing Set, camshaft R Bearing, for one connecting rod (STD) RA008 8 Piston w/pin, (STD) 4 R004 8 Ring Set, piston (STD) RA00 8 Connecting Rod (STD) 6 TBD 6 Bolt, connecting rod cap 7 TBD Bolt, rear engine cover 8 RA806 Flywheel Assembly 9 R Bolt, fl ywheel attaching 0 R0476 Seal, crankshaft rear oil TBD Cover, rear engine TBD Gasket, rear engine cover p/o item #4 Reluctor Ring, crankshaft 4 TBD Crankshaft Assembly TBD Bearing Set, crankshaft 6 TBD Cap, crankshaft bearing # and # 7 TBD 0 Bolt, crankshaft bearing cap side 8 TBD Cap, crankshaft bearing # - #4 9 TBD Stud, crankshaft bearing cap attaching 0 TBD Bolt, crankshaft bearing cap attaching R06406 Balancer, crankshaft TBD Bolt, crankshaft balancer TBD Oil Pump Assembly 4 R0404 Drive, oil pump TBD Key, crankshaft 6 TBD Chain, timing 7 TBD Valve, camshaft position actuator solenoid 8 TBD Actuator, camshaft position 9 TBD Bolt, camshaft retainer attaching 0 TBD Retainer, camshaft/phasor TBD Camshaft TBD Tensioner Kit, includes items,, 6 TBD Bolt, camshaft tensioner retainer L PCM ZR409

8 MODEL MP6.0L PARTS MANUAL - 6 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE OR 0 B NON-CATALYST A PC60P_004b-08 0/4/008 - nc PCM ZR409 L007-08

9 MODEL MP6.0L PARTS MANUAL - 7 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID TBD Hose, PCV valve TBD Valve, positive crankcase ventilation (PCV) TBD Grommet, PCV valve 4 TBD 6 Rocker Arm, valve TBD 6 Bolt, valve rocker arm attaching 6 TBD Guide, valve rocker arm 7 TBD 6 Valve Spring Assembly 8 TBD Retainer, valve stem Bolt, lifting eye attaching Lockwasher, lifting eye attaching bolt A R040 Lifting Eye, rear, B R0406 Lifting Eye, front TBD 6 Cap, valve spring TBD 6 Seal, valve stem 4 TBD Rotator, valve TBD 6 Guide, valve stem 6 RP000 8 Spark Plug 7 RK00 Spark Plug Wire Set 8 R00046 Engine Coolant Temperature (ECT) Sensor 9 TBD 8 Valve, exhaust (STD) 0 TBD 8 Valve, intake (STD) TBD 8 Bolt, valve lifter retainer attaching R Retainer, valve lifter RM080 Gasket, front engine cover 4 TBD Cover, front engine R0477 Seal, front engine cover oil 6 RM08 Gasket, water circulating pump 7 RK0706 Water Circulation Pump Assembly 8 TBD 4 Bolt, water circulating pump attaching 9 RM07 Gasket, thermostat housing 0 R006 Housing, thermostat 9806 Bolt, thermostat housing attaching Lockwasher, thermostat housing attaching 86 Plug, thermostat housing 4 R0600 Thermostat, (60 F) R090 Plate, thermostat retainer 6 RS Plug, water neck 7 R0408 Water Neck 8 RS Plug, water neck 9 TBD 8 Bolt, front engine cover attaching L PCM ZR409

10 MODEL MP6.0L PARTS MANUAL - 8 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE (cont d) OR 0 B NON-CATALYST A PC60P_004b-08 0/4/008 - nc PCM ZR409 L007-08

11 MODEL MP6.0L PARTS MANUAL - 9 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE (cont d) ITEM PART NO. QTY. DESCRIPTION MODEL ID 40 R Lifter, valve 4 R Push Rod 4 RM078 Gasket, Cylinder Head 4 R0006 Cylinder Head 44 R Bolt, cylinder head (short) 4 R Bolt, cylinder head (medium) 46 R Bolt, cylinder head (long) 47 RA006 Cover, rocker (LH) 48 RM08 Gasket, rocker cover 49 R Bolt, rocker cover attaching 0 R049 Tube, breather 0 TBD Tube, breather, SN and higher R04049 Tube, oil fi ll R0408B Cap, oil fi ll tube TBD Fitting, breather tube 4 RA007 Cover, rocker w/oil Fill (RH) L PCM ZR409

12 MODEL MP6.0L PARTS MANUAL - 0 EXHAUST MANIFOLD / KNOCK SENSORS - FIGURE PC60P_ PCM ZR409 L007-08

13 MODEL MP6.0L PARTS MANUAL - EXHAUST MANIFOLD / KNOCK SENSORS - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID TBD Bolt, coolant air bleed pipe attaching RA0804 Pipe, coolant air bleed NSS Sensor, oil pressure (Not Used) 4 TBD Bolt, crankshaft position attaching TBD Sensor, crankshaft position 6 TBD 0 Bolt, valley cover attaching 7 R000 Sensor, knock 8 TBD Cover, valley 9 TBD Gasket, valley cover 0 TBD Bolt, TBD Block-off, TBD Seal, R0906 Elbow, exhaust 4 RM074 Gasket, exhaust elbow to manifold R080 Manifold, exhaust 6 R00 Stud, exhaust manifold attaching Lockwasher, exhaust manifold stud attaching Nut, exhaust manifold stud attaching 9 RS9 Plug, exhaust elbow 9 R00047 Switch, exhaust temperature (optional) L PCM ZR409

14 MODEL MP6.0L PARTS MANUAL - INTAKE MANIFOLD COMPONENTS - FIGURE LY6_INTK.ai 0//008 - nc PCM ZR409 L007-08

15 MODEL MP6.0L PARTS MANUAL - INTAKE MANIFOLD COMPONENTS - FIGURE 4 ITEM PART NO. QTY. DESCRIPTION MODEL ID R70 Bolt, engine cover attaching R Insert, engine cover R06007 Cover, engine 4 R704 8 Coil, ignition R0909 Bracket, ignition coil mounting (port) R09046 Bracket, ignition coil mounting (stbd) Bolt, fuel rail attaching 6 RS66 Bolt, fuel rail attaching/coil bracket attac`hing Lockwasher, fuel rail attaching/coil bracket attaching 7 R09068 Bracket, support 8 RK00 Spark Plug Wire Set 9 R8004 Cap, vacuum 0 R0006 Sensor, manifold absolute pressure (MAP) 0 TBD Sensor, manifold absolute pressure (MAP) SN and higher TBD Seal, throttle body TBD Stud, throttle body attaching, upper TBD Bolt, throttle body attaching, lower 4 TBD Throttle Body Assembly L0098 Nut, throttle body attaching 6 TBD Intake Manifold 6 TBD Intake Manifold, SN and higher 7 RA Fuel Injector Assembly 7 TBD 8 Fuel Injector Assembly, SN and higher NI RK047 Kit, O Ring 6.0L fuel injector NI TBD Kit, O Ring 6.0L fuel injector, SN and higher 8 R Retainer, fuel injector to rail Bolt, coil bracket attaching Lockwasher, coil bracket attaching Bolt, ignition coil attaching TBD Gasket Set, intake manifold TBD Decal, engine cover, side - ZR409 4 TBD Fuel Rail, assembly R0907 Bracket, support, coil bracket (port) R0908 Bracket, support, coil bracket (stbd) Bolt, support bracket attaching Lockwasher, support bracket attaching Nut, support bracket attaching 9 R489 Decal, engine cover, front, PCM 0 TBD 0 Bolt, intake manifold mounting L PCM ZR409

16 MODEL MP6.0L PARTS MANUAL - 4 OIL PAN and OIL PUMP ASSEMBLY - FIGURE PCM ZR409 L007-08

17 MODEL MP6.0L PARTS MANUAL - OIL PAN and OIL PUMP ASSEMBLY - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID R04079 Tube, oil dipstick R04080 Dipstick, oil level (0 to 4 degree) RS00 Bolt, oil dipstick tube attaching 4 R70 Clamp, oil dipstick tube attaching RS80 Lockwasher, oil dipstick tube attaching 6 RS08 Nut, oil dipstick tube attaching 7 TBD Bolt, engine rear cover attaching 8 R0476 Seal, engine rear cover oil 9 TBD Cover, engine rear 0 R07400 Tube, oil pickup RM079 Gasket, oil pan R000 Oil Pan TBD Bolt, oil sending unit adapter attaching 4 R07907 Adapter, oil sending unit RM084 Gasket, oil sending unit adapter 6 TBD Bolt, oil pan attaching (long) 7 R04 Fitting, oil drain 8 R04049 AR Hose, oil drain 9 R0406 Fitting, oil drain 0 R04066A Cap, oil drain R90 Hook, oil drain hose TBD Bolt, oil pan attaching (short) TBD Nut, oil pickup tube attaching 4 TBD Bolt, oil pickup tube attaching TBD 0 Nut, windage tray attaching 6 TBD O-ring, oil pickup tube 7 R007 Tray, windage 8 TBD 4 Bolt, oil pump attaching 9 RA07008 Oil Pump Assembly 0 TBD Drive, oil pump TBD Check Valve, oil pressure L PCM ZR409

18 MODEL MP6.0L PARTS MANUAL - 6 THROTTLE BODY and RELATED COMPONENTS - FIGURE PC60P_00_08 0//008 PCM ZR409 L007-08

19 MODEL MP6.0L PARTS MANUAL - 7 THROTTLE BODY and RELATED COMPONENTS - FIGURE 6 ITEM PART NO. QTY. DESCRIPTION MODEL ID RA900 Throttle Control Position (TCP) Sensor Assembly Bolt, TCP Sensor Assembly attaching Washer, fl at, TCP Sensor Assembly attaching 4 RS0 Nut, TCP Sensor Assembly attaching R Cable Clip, throttle 6 RS Bolt, cable clip attaching 7 RS00 Nut, cable clip attaching 8 TBD Bracket, TCP Assembly/Throttle Clip Bolt, TCP/Throttle Clip bracket attaching 0 TBD Throttle Body Assembly RS87 Clamp, fl ame arrestor NSS Air Temp Sensor (order R408) R408 Arrestor, fl ame Bolt, TCP Sensor attaching Lock Washer, TCP Sensor attaching Flat Washer, TCP Sensor attaching 7 R090A Plate Assembly, TCP Sensor 8 RS68 Nut, ball joint attaching 9 R7800 Ball Joint Assembly 0 R08009 Arm, TCP Sensor Bolt, TCP Sensor arm attaching Lock Washer, TCP Sensor arm attaching Flat Washer, TCP Sensor arm attaching 4 R0807 Shaft, TCP Sensor R06090 Spacer, TCP support 6 R900 TCP Sensor 7 R060069A Cover, fl ame arrestor 8 R0904 Bracket, fl ame arrestor cover, upper 9 RS60 Bolt, cover mount attaching, upper (use removable locktite) Lockwasher, cover mount attaching, upper R0708 Coupling, nut cover mount, upper R0964 Washer, cover attaching, upper R70 Bolt, cover attaching, upper (use removable locktite) 4 R09040 Bracket, cover fl ame arrestor, lower R707 Screw, bellt guard retaining 6 R07084 Nut, Clip-on L PCM ZR409

20 MODEL MP6.0L PARTS MANUAL - 8 REMOTE OIL FILTER COMPONENTS (STANDARD DRIVE) - FIGURE PC60P_ PCM ZR409 L007-08

21 MODEL MP6.0L PARTS MANUAL - 9 REMOTE OIL FILTER COMPONENTS (STANDARD DRIVE) - FIGURE 7 ITEM PART NO. QTY. DESCRIPTION MODEL ID 9900 Bolt, oil fi lter header mounting RS79 Lockwasher, oil fi lter header mounting R Oil Filter Header 4 R0907 Bracket, oil fi lter header mounting R00049 Sender, oil pressure 6 R044 Tee, sender attaching 7 RS4 Plug, oil pressure sensor tee 8 R07907 Adapter, oil sending unit 9 R04740 O-ring, oil bypass adapter 0 R Adapter, oil bypass R0470 O-ring, oil bypass adapter attaching fi tting R Nut, oil bypass adapter attaching thru SN 4867 R07907 Nut, oil bypass adapter attaching SN and higher R0484 Fitting, 90 degree 4 R040D Hose Assembly, fi lter header to bypass adapter R040D Hose Assembly, bypass adapter to fi lter header 6 R0448 Fitting, straight 7 R07700 Filter, oil 8 R040 Nipple, header fi lter adapter 9 R0474 O-Ring, oil line 0 R47 Decal, CAUTION HOT R Adapter, engine to oil bypass TBD Adapter, engine to oil bypass SN48676 and higher L PCM ZR409

22 MODEL MP6.0L PARTS MANUAL - 0 REMOTE OIL FILTER COMPONENTS ( V - DRIVE) - FIGURE PC60P_ PCM ZR409 L007-08

23 MODEL MP6.0L PARTS MANUAL - REMOTE OIL FILTER COMPONENTS ( V - DRIVE) - FIGURE 8 ITEM PART NO. QTY. DESCRIPTION MODEL ID R0907 Bracket, oil fi lter header mounting R Oil Filter Header R040 Nipple, header fi lter adapter 4 R07700 Filter, oil RS79 Lockwasher, oil fi lter header mounting Bolt, oil fi lter header mounting 7 RA040 Hose Assembly, bypass adapter to fi lter header 8 RA040 Hose Assembly, fi lter header to bypass adapter 9 R0484 Fitting, 90 degree 0 R Nut, oil bypass adapter attaching thru SN R07907 Nut, oil bypass adapter attaching SN and higher R0470 O-ring, oil bypass adapter attaching fi tting R Adapter, oil bypass R04740 O-ring, oil bypass adapter 4 R07907 Adapter, oil sending unit RS4 Plug, oil pressure sensor tee 6 R044 Tee, sender attaching 7 R00049 Sender, oil pressure 8 R0474 O-Ring, oil line 9 R47 Decal, CAUTION HOT 0 R Adapter, engine to oil bypass thru SN TBD Adapter, engine to oil bypass SN48676 and higher L PCM ZR409

24 MODEL MP6.0L PARTS MANUAL - FUEL CONTROL CELL (FCC) COMPONENTS - FIGURE 9 0 FCC V-Drive Bracket OUT PN: R08004 IN 4 PCM ZR409 L007-08

25 MODEL MP6.0L PARTS MANUAL - FUEL CONTROL CELL (FCC) COMPONENTS - FIGURE 9 ITEM PART NO. QTY. DESCRIPTION MODEL ID R700 Locking Clip, fuel line RA08090C Hose Assembly, FCC to fuel rail (inlet) RA08090E Hose Assembly, FCC to fuel rail (inlet) xx-60v-xx R09076 Bracket, FCC mounting R09077A Bracket, FCC mounting xx-60v-xx Bolt, FCC mounting Bolt, FCC mounting bracket Lockwasher, FCC mounting bracket 7 RA0800 FCC Assembly 8 R4C Decal, FCC 9 R08004A Filter, primary fuel Connector, W/P -Way Female R008A Harness, piece, FCC high pressure fuel pump R047 Fitting, FCC head (fuel supply line) RS0 Plug, FCC head 4 R04 Fitting, 90 degree R049 Fitting, FCC internal 6 R000 Baffle, fuel Screw, self-tapping, baffl e/harness retaining 8 R0474 O Ring, FCC bowl-to-head seal 9 R Regulator, fuel pressure 0 R Retainer, fuel pressure regulator R04098B Hose, FCC internal fuel R7087 Clamp, Oeticker RA08007 Pump, FCC high pressure fuel 4 R08006 Filter, FCC R700 Clamp, FCC bowl-to-head retaining 6 R800 Cover, FCC clamp T-bolt 7 R70 U-Bolt, low pressure fuel pump retaining Nut, Nylock, low-pressure fuel pump retaining 9 RS4 Plug, FCC drain 0 R047 O Ring, LPFP seal RA0800 Fuel Pump, low-pressure R09404 Isolator, LPFP mounting R69064 AR Shim, LPFP mounting, gage R69064A AR Shim, LPFP mounting, 6 gage R69064B AR Shim, LPFP mounting, gage 4 R04 Fitting, LPFP to /8 Hose barb R047 O Ring, seal (p/o item ) NI R44 Decal, Warning, fuel leaks NI RP08006 Kit, Filter and O-Rings, FCC L PCM ZR409

26 MODEL MP6.0L PARTS MANUAL - 4 HEAT EXCHANGER and COMPONENTS - FIGURE PC60P_ PCM ZR409 L007-08

27 MODEL MP6.0L PARTS MANUAL - HEAT EXCHANGER and COMPONENTS - FIGURE 0 ITEM PART NO. QTY. DESCRIPTION MODEL ID R0404 Cap, degas bottle R4600 Bottle, degas NI TBD Decal, 6.0L specifi cation NI R4 Decal, coolant fi ll RS87 Clamp, hose 4 R046 Hose, degas bottle to heat exchanger R68008 AR Anode, sacrifi cial zinc 6 RS078 Nut, ground wire stud 7 R00 Wire, grounding 8 RA47047 Heat Exchanger Assembly 9 R04009 AR End Cap, exchanger 0 R Isolator, rubber R09079B Bracket, heat exchanger RS004 Bolt, heat exchanger bracket attaching RS80 Lockwasher, mounting bolt 4 RS87 Clamp, exchanger mounting R09074A Bracket, degas bottle mounting 6 TBD Bolt, degas bottle bracket attaching 7 TBD Nut, degas bottle bracket attaching NI R4 Decal, Protective Anode NI R46 Decal, Raw Water Drain NI R47 Decal, Fresh Water Drain L PCM ZR409

28 MODEL MP6.0L PARTS MANUAL - 6 FRESH WATER COOLING SYSTEM COMPONENTS - FIGURE TO DRIPLESS SHAFT SEAL PCM ZR409 L007-08

29 MODEL MP6.0L PARTS MANUAL - 7 FRESH WATER COOLING SYSTEM COMPONENTS - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID R04 Hose, exchanger to exhaust manifold (Starboard STD) RS87 Clamp, hose R046 Hose, degas bottle to heat exchanger 4 R0404 Cap, degas bottle R4600 Bottle, degas 6 R7087 Clamp, hose (/8 - degas bottle) 7 R04 Hose, coolant air bleed to bottle 8 RS8 4 Clamp, hose ( ) 9 R0449A Hose, circ. pump to heat exchanger 0 RS868 Clamp, hose ( / ) R0448 Hose, exchanger to thermostat housing R040 Hose, exchanger to exhaust manifold (Port STD) R04006A Fitting, 90 degree 4 R4704 Cooler, transmission oil 86 Plug, manifold 6 RA0804 Tube, coolant air bleed 7 RM08 Gasket, water pump to engine block 8 RK0706 Water Circulation Pump Assembly 9 RA070 Raw Water Pump Hose, oil cooler to raw water pump (cut-to-fi t) R0447 Hose, raw water pump to exchanger RM07 Gasket, thermostat housing R006 Thermostat Housing 4 R090 Plate, thermostat retainer R0600 Thermostat, (60 degree) 6 R0408 Water Neck 6A RS Plug,water neck 7 R04 Hose, coolant bypass fi tting (/4 bulk) 8 R040A Bypass, coolant, U-Tube, / NPTF 8 R040B Bypass, coolant, U-Tube, / NPTM, SN and higher 9 R04086 Hose, coolant bypass fi tting (/8 bulk) 0 R0407 Fitting, manifold straight RS88 0 Clamp, hose ( /4 ) R7087G Clamp, hose ( /6 oetiker) R7087F Clamp, hose ( oetiker) 4 R7084 Clamp, hose (vent tube) R044 AR Fitting, /8 NPT x /6 hose 6 R0449 Tee, /4 to / NPTF 6 R0449A Tee, /4 to / NPTM, SN and higher 7 R009 Ball Valve, / NPTM X/NPTF 7 R009A Ball Valve, / NPTF X/NPTF, SN and higher AR Fitting, / NPT x /8 hose NI AR Plug, / NPT, soc NI RF009A AR Heater Retrofit Kit, includes items 8, 6, 7 L PCM ZR409

30 MODEL MP6.0L PARTS MANUAL - 8 OPTIONAL DRAIN KIT COMPONENTS - FIGURE 4 DRAIN = Drain Kit The drain kit does not ensure that all of the water will drain out of the system. Engine angle, routing of drain hose, and restricted drain fittings are some things that could prevent all of the water from draining completely. PCM ZR409 L007-08

31 MODEL MP6.0L PARTS MANUAL - 9 OPTIONAL DRAIN KIT COMPONENTS - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID R048 4 Fitting, straight R04 Tee, hose RS7 Plug, drain 4 R046 Fitting, 4-way RW drain R047 AR Hose, RW drain NS R7087G 0 Clamp, hose ( /6 oetiker) NS R7087F Clamp, hose ( oetiker) L PCM ZR409

32 MODEL MP6.0L PARTS MANUAL - 0 EXHAUST MANIFOLD and COMPONENTS - FIGURE PC60P_ PCM ZR409 L007-08

33 MODEL MP6.0L PARTS MANUAL - EXHAUST MANIFOLD and COMPONENTS - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID Nut, exhaust elbow attaching Lockwasher, exhaust elbow attaching RM074 Gasket, manifold to exhaust elbow 4 R006 4 Stud, exhaust elbow attaching (short) 4 R009 AR Stud, exhaust elbow attaching w/4 riser (short) R080 Exhaust Manifold Assembly 6 R00 Stud, manifold to cylinder head attaching 7 RS79 Lockwasher, manifold to cylinder head attaching 8 RS706 Nut, manifold to cylinder head attaching 9 RM076A Gasket, manifold to cylinder head 0 R0906 Exhaust Elbow Assembly R007 4 Stud, exhaust elbow attaching (long) R0040 AR Stud, exhaust elbow attaching w/4 riser (long) R00047 Switch, exhaust temperature (optional) NI RS9 Plug, exhaust elbow R09644 Retainer, spark plug wire clip Washer, retainer attaching RS080 Bolt, retainer attaching Bolt, bracket attaching Lockwasher, bracket attaching Bolt, bracket attaching 9 R0900 Bracket, manifold support 0 R400K Decal, exhaust manifold, 6.0L RS7 4 Plug, Hex Head, Brass /8 NPT *NOTE: See Fresh Water Cooling section for parts used on Fresh Water Cooled engines. L PCM ZR409

34 MODEL MP6.0L PARTS MANUAL - EXHAUST MANIFOLD 4 SPACER KIT COMPONENTS - FIGURE PC PCM ZR409 L007-08

35 MODEL MP6.0L PARTS MANUAL - EXHAUST MANIFOLD 4 SPACER KIT COMPONENTS - FIGURE 4 ITEM PART NO. QTY. DESCRIPTION MODEL ID Nut, exhaust elbow attaching -60V-XX Lockwasher, exhaust elbow attaching -60V-XX RM074 4 Gasket, manifold/spacer and spacer/elbow -60V-XX 4 R009 4 Stud, exhaust elbow attaching w/4 riser (short) -60V-XX R06086 Spacer, 4-60V-XX 6 R Stud, exhaust elbow attaching w/4 riser (long) -60V-XX NI RK06086 AR Kit, riser -60V-XX L PCM ZR409

36 MODEL MP6.0L PARTS MANUAL - 4 RAW WATER COOLING PUMP - FIGURE PC60P_ PCM ZR409 L007-08

37 MODEL MP6.0L PARTS MANUAL - RAW WATER COOLING PUMP - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID Bolt, bearing housing attaching Lockwasher, bearing housing attaching bolt R0474 O-ring, bearing housing attaching bolt 4 R0474 O-ring, bearing housing attaching RP060 Impeller Kit (includes O-rings and impeller) 6 R070 Housing, raw water pump 7 RA407 Bearing Housing Assembly 8 RA070 Raw Water Pump Assembly 9 R706 Bolt, raw water pump cam 0 R0474 O-ring, raw water pump cam R608 Cam, raw water pump RS4 Plug, brass /8 NPT L PCM ZR409

38 MODEL MP6.0L PARTS MANUAL - 6 WIRING HARNESS ASSEMBLIES and SENDERS - FIGURE Cruise MPH Set (+)/Res 8 7 Cruise RPM Speed Cancel Speed (-) PC60P_0_ nc PCM ZR409 L007-08

39 ITEM PART NO. QTY. DESCRIPTION MODEL ID MODEL MP6.0L PARTS MANUAL - 7 WIRING HARNESS ASSEMBLIES and SENDERS - FIGURE 6 R078 AR Harness, FCC ( V - Drive) RA099 Engine Wiring Harness Assembly xx-60x-xx RA06 Engine Wiring Harness Assembly SN and higher xx-60x-xx w/auto-start R00046 Sensor, engine coolant temperature (ECT) 4 R000 Sensor, inlet air R00049 Sender, oil pressure 6 R044 Tee, sender attaching 7 R07907 Adapter, oil sending unit 8 RS4 Plug, oil pressure sensor tee 9 R0A Harness, ignition coil 0 RA008 AR Panel, switch (Speed Control) RA098 AR Harness, Adapter to 4-pin boat harness RA094 AR Harness, Adapter to 8-pin (female) boat harness NI RA094A AR Harness, Adapter to 8-pin (male) boat harness RA09 AR Harness, Adapter to 0-pin boat harness NI RA09A AR Harness, Adapter to 0-pin boat harness, w/vdo sensor leads NI RA09B AR Harness, Speed Control (4 foot) NI RA09 AR Harness, Engine to Dash, Un-Terminated ( foot) NI RA09C AR Harness, Engine to Dash, Un-Term., w/vdo sensor leads( ft) 4 RT009 AR Harness, Test w/key Switch L PCM ZR409

40 MODEL MP6.0L PARTS MANUAL - 8 ECM and RELAYS - FIGURE FUEL PUMP RELAY IGNITION RELAY STARTER 0A PANEL 40A 6 STARTER RELAY FUEL PUMP IGNITION 0A 0A ECM IGNITION 0A 0A VSW DIAG COMM A A PC60P_ PCM ZR409 L007-08

41 ECM and RELAYS - FIGURE 7 ITEM PART NO. QTY. DESCRIPTION MODEL ID RS00 Bolt, oil dipstick tube attaching R70 Clamp, oil dipstick tube attaching RS80 Lockwasher, oil dipstick tube attaching 4 RS08 Nut, oil dipstick tube attaching R604 Engine Control Module xx-60-xx - Direct Drive R604 Engine Control Module xx-60v-xx - V-Drive R604 Engine Control Module xx-60-xx - Direct Drive - Auto-Start, SN and higher R604 Engine Control Module xx-60v-xx - V-Drive - Auto-Start, SN and higher Bolt, ECM attaching 7 RS67 4 Flat washer, ECM attaching Nut, KEPS, ECM attaching 9 R Isolator, fuse block mounting 0 RS78 Lockwasher, Isolator attaching RS0 Bolt, Isolator attaching RS078 Nut, KEPS, Fuse Block attaching R09079A Bracket, ECM/Heat Exchanger mounting 4 RS80 Lockwasher, ECM bracket attaching bolt RS004 Bolt, ECM bracket attaching 6 TBD Decal, main fuse box 7 R00 Relay, Fuel Pump and Ignition 8 R006 Relay, Starter 9 R09C Fuse, Starter, 0 Amp 0 R09F Fuse, Panel, 40 Amp R07B 4 Fuse, 0 amp R07A Fuse, amp R07C Fuse, amp 4 R Isolator, ECM Mounting R760 4 Sleeve, ECM Isolator Retaining MODEL MP6.0L PARTS MANUAL - 9 L PCM ZR409

42 MODEL MP6.0L PARTS MANUAL - 40 ACCESSORY DRIVE SYSTEM COMPONENTS - FIGURE 8 Belt Tensioner Alternator Idler Circulation Pump Raw Water Pump Crankshaft Pulley A PC60P_0_08a nc PCM ZR409 L007-08

43 MODEL MP6.0L PARTS MANUAL - 4 ACCESSORY DRIVE SYSTEM COMPONENTS - FIGURE 8 ITEM PART NO. QTY. DESCRIPTION MODEL ID R0660 Belt, serpentine drive p/o item # Bolt, tensioner pulley attaching p/o item # Washer, tensioner pulley attaching bolt 4 p/o item # Pulley, tensioner RA06800 Tensioner, belt Bolt, idler pulley attaching 7 RS79 Lockwasher, idler pulley attaching bolt Washer, idler pulley attaching bolt (small) 9 R0964 Washer, formed, idler pulley attaching bolt (large) 0 R06040 Pulley, idler R09069 Bracket, idler pulley mounting / alternator Lockwasher, idler pulley bracket attaching bolt Bolt, idler pulley bracket attaching Bolt, alternator mounting, lower RA070 Raw Water Pump Assembly Bolt, raw water pump mounting 7 R0600 Pulley, raw water pump Flat Washer, raw water pump pulley attaching Lockwasher, raw water pump pulley attaching bolt Bolt, raw water pump pulley attaching R06406 Balancer, crankshaft TBD Bolt, crankshaft balancer TBD 4 Bolt, water circulation pump attaching 4 TBD Bolt, belt tensioner mounting RA Alternator Assembly, 00 Amp NI RF097009C AR Retro Fit Kit, 70 to 00 Amp Alternator 6 TBD Pulley, alternator (00 amp) Flatwasher, alternator mounting 8 RS79 Lockwasher, alternator mounting Bolt, alternator mounting, upper 0 R447 Decal, belt routing RK0706 Water Circulation Pump Assembly Nut, KEPS, Alternator Positive Post, 00A NI R006 Wire, Ground, alternator 00A NI R08D Wire, Charge, 00A Fuse Link - alternator to starter Nut, belt guard bracket attaching Lockwasher, belt guard bracket attaching RS79 Washer, fl at, belt guard bracket attaching 6 R09066 Bracket, belt guard, upper port 7 R09040 Bracket, belt guard, upper starboard 8 R707 Screw, bellt guard retaining 9 R Cover, Belt guard 40 R Grommet, belt guard retaining 4 R09067 Bracket, front cover, lower 4 R07084 Nut, Clip-on L PCM ZR409

44 MODEL MP6.0L PARTS MANUAL - 4 STARTER ASSEMBLY COMPONENTS - FIGURE PC60P_ PCM ZR409 L007-08

45 MODEL MP6.0L PARTS MANUAL - 4 STARTER ASSEMBLY COMPONENTS - FIGURE 9 ITEM PART NO. QTY. DESCRIPTION MODEL ID RS709 Nut, solenoid terminal RS00 Lockwasher, solenoid terminal RU000A Solenoid, starter 4 R0090 Bolt, starter mounting RA09 Starter Motor Assembly Lockwasher, solenoid terminal 7 RS706 Nut, solenoid terminal L PCM ZR409

46 MODEL MP6.0L PARTS MANUAL - 44 ENGINE and TRANSMISSION MOUNTS - FIGURE 0 Engine Mount Group Front Mount Engine Mount Group Rear Mount a 6 4 b a a/b 4 4 PC60P_09b-08a PCM ZR409 L007-08

47 ENGINE and TRANSMISSION MOUNTS - FIGURE 0 ITEM PART NO. QTY. DESCRIPTION MODEL ID R0900 Bolt, trunnion clamp Lockwasher, engine mount attaching bolt Bolt, engine mount attaching 4 R0904 Mount, engine front RS8 Lockwasher, trunnion clamp bolt 6 RS9 Nut, trunnion clamp bolt 7 RS07 4 Nut, adjustment and lock 8 RS86 Lockwasher, adjusting nut 9 R0900 Trunnion, long 9 R09007 Trunnion, short 0 RC0900 Trunnion Assembly RA0906 Trunnion Assembly MODEL MP6.0L PARTS MANUAL - 4 RA090 Trunnion Assembly, tall (.: STD / V-drive) 04-6xxV-xx Used with item #7 - R0904 mount a RA090A Trunnion Assembly, tall (.: STD / V-drive) Used with item #6 - R0900 mount b RA0900 Trunnion Assembly, short (.0: STD) 04-6xxV-xx, 0-6xxV-xx Used with item #7 - R0904 mount c RA09006 Trunnion Assembly, short (.0: STD) Used with item #6 - R0900 mount R0900 Trunnion,. (use with R0904) R09006 Trunnion,. (use with R0900) 4 RS07 4 Bolt, rear mount attaching (R0904, R0908/8A-lower) 4 RS08 4 Bolt, rear mount attaching (R0904, R0900//4/) 4 RS09 4 Bolt, rear mount attaching (R0900) 4 RS00 4 Bolt, rear mount attaching (R0908A, upper) 4 RS04 4 Bolt, rear mount attaching (R0908, upper) RS8 4 Lockwasher, rear mount attaching bolt 6 R0900 Mount, rear 7 R0904 Mount, rear NI R0904 Mount, rear, port -6xxV-0 NI R09044 Mount, rear, starboard -6xxV-0 NI 9790 Mount, engine support (dual rear) 0-6xxV-0, 0-6xxV-0 NI Lockwasher, engine mount attaching bolt (item #8) NI Bolt, engine mount attaching, upper (item #8) NI Bolt, engine mount attaching, lower (item #8) 8 R6906 AR Shim, Mount, rear 0-6xx-0 NI R6906 AR Spacer, Mount, rear, 04-6xxV-0 9 R0908 Mount, PCM V-DRV (use with RA0906, item ) 0 R0904 Plate, brace, PCM V-DRV used when there is no mount -6xxV-0 RS09 4 Nut, rear mount attaching (R0908) RS8 4 Lockwasher, rear mount attaching (R0908) Bolt, shim mount attaching (R6906) 4 R0904 Mount, rear, transmission, PCM V-DRV, port 4 R090 Mount, rear, transmission, PCM V-DRV, starboard R0900 Mount, rear, transmission, PCM V-DRV, port 04-6xxV-xx R090 Mount, rear, transmission, PCM V-DRV, starboard 04-6xxV-xx 6 R6906 Spacer, Mount, rear, 04-6xxV-xx 7 R0907 Bracket, PCM VDRV mount support 04-6xxV-xx 8 R09070 Bracket, PCM VDRV mount support 9 RA0906 Trunnion Assembly, with R0900 trunnion 0 R0909 Mount, engine front (port).: 0 R09094 Mount, engine front (starboard).: 0 R0900 Mount, engine front (port).0: 0 R0900 Mount, engine front (starboard).0: L PCM ZR409

48 PLEASURECRAFT ENGINE GROUP MADE IN USA MODEL MP6.0L PARTS MANUAL - 46 BELL HOUSING ASSEMBLY - FIGURE POWER PLUS RATIO PC60P_0_ PCM ZR409 L007-08

49 MODEL MP6.0L PARTS MANUAL - 47 BELL HOUSING ASSEMBLY - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID RA70 AR Transmission Assembly, IRM40S, PCM to PCM V-DRV R00 8 Stud, PCM V-DRV to transmission attaching RS79 8 Lockwasher, PCM V-DRV to transmission attaching 4 RS706 8 Nut, PCM V-DRV to transmission attaching RA60B AR PCM Power-Plus V-Drive Assembly,.48: NI R900 AR Gear Lube, synthetic SAE 0, PCM V-DRV 6 TBD Plug, brass, oil fi ll/drain, PCM V-DRV Fitting, brass elbow 90, PCM V-DRV 8 RS6 Plug, brass, raw water drain, / square socket 9 RA707 AR Transmission Assembly, IRM40A,.: PCM 0 RA6009 AR Transmission Assembly, 60V, HURTH,.9: 0-60V-0 0 RA6009A AR Transmission Assembly, 60V, HURTH,.: 0-60V-0, 04-60V-0 RA706 AR Transmission Assembly, IRM40I,.0: PCM R07906 AR Adapter, V-Drive, PCM to Walter NI RM09 AR Gasket, V-Drive, PCM to Walter RA700 AR Transmission Assembly,.0: Warner (7C) RA700 AR Transmission Assembly,.0: Warner (7C) RA700A AR Transmission Assembly, (7C w/v-drive adapter)) 4 R07907 AR Adapter, V-Drive, Warner to Walter RA6004 AR V-Drive Assembly, Walters,.46: 6 RA600 AR Transmission Assembly, 90VTS, ZF -speed 04-60V-0 NI RK040 AR Connector Kit, ZF -speed 7 98 Plate, damper (Warner Transmissions, 6.0/8.L) 7 R4006 Plate, damper (PCM Transmissions) 7 R4008 Plate, damper (Hurth Transmission/-speed) Lockwasher, damper plate attaching bolt Bolt, damper plate attaching 0 R090A Cover, dust, (stbd) (use w/top mount starter) 0 R090 Cover, dust (stbd) (use w/bottom mount starter) R090 Cover, dust (port) Lockwasher, dust cover attaching RS60 Bolt, dust cover attaching 4 RS078 Nut, dust cover attaching RS06 Bolt, dust cover attaching 6 R004 Stud, bellhousing attaching Lockwasher, bellhousing attaching Nut, bellhousing attaching Bolt, bellhousing attaching Lockwasher, bellhousing attaching R404 Bellhousing, top or bottom mount starter R4006B Bellhousing, bottom mount starter, only NI R0900 Cover, dust, top mount starter (used w/r09008a) NI RS07 Bolt, dust cover attaching NI RS8 Lockwasher, dust cover attaching ** PCM ** RS80 4 Lockwasher, transmission attaching bolt RS09 4 Bolt, transmission attaching **Velvet Drive ** NI 964 Stud, transmission mounting (4 ) NI RS8 6 Lockwasher, transmission mounting NI RS09 Nut, transmission mounting stud NI RS07 4 Bolt, transmission mounting **Hurth Gears** NI R008 Stud, transmission mounting ( /8 ) NI RS8 6 Lockwasher, transmission mounting NI RS09 Nut, transmission mounting stud NI RS09 4 Bolt, transmission mounting L PCM ZR409

50 MODEL MP6.0L PARTS MANUAL - 48 TRANSMISSION AND RELATED COMPONENTS (STANDARD DRIVE) - FIGURE A - FRONT MOUNT SHIFT BRACKET PCM V-DRV SHIFT BRACKET Used w/r A A PC60P_08_ PCM ZR409 L007-08

51 MODEL MP6.0L PARTS MANUAL - 49 TRANSMISSION AND RELATED COMPONENTS (STANDARD DRIVE) - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID R Cable Clip, single cable RS Bolt, cable clip attaching R0904A Bracket, shift 4 RS0 Nut, cable clip attaching bolt R0909 Bracket, shift (PCM V-DRV) A R0909A Bracket, shift (PCM V-DRV) SN and higher 6 R09048 Bracket, shift (PCM V-DRV, attaches to R0904) 7 RS4 Bolt, bracket attaching 8 RS078 Nut, KEPS, bracket attaching bolt 9 R0400 Fitting, 90 degree 0 R040 Fitting, 4 degree RA707 Transmission,.: RA706 AR Transmission,.0: RA04007S Hose Assembly, cooler to transmission R0400 Fitting, 90 degree 4 R4704 Transmission Cooler Assembly RA04007T Hose Assembly, transmission to cooler 6 R4800 OPT Coupler, prop shaft (4 X shaft) 6 R480 OPT Coupler, prop shaft (4 X /8 shaft) Screw, set - coupler 8 R0400 Fitting, 90 degree 9 R09000 Clamp, cooler assembly mounting 0 RS06 Bolt, cooler attaching RS078 Nut, cooler attaching RS00 Bolt, cooler clamp attaching R0900A Bracket, cooler mounting 4 RS80 Lockwasher, cooler clamp attaching bolt RS08 Nut, oil cooler clamp attaching bolt 6 R090 Bracket, shift, rear entry L PCM ZR409

52 MODEL MP6.0L PARTS MANUAL - 0 TRANSMISSION AND RELATED COMPONENTS (.0: V - DRIVE) - FIGURE PCB706_06a-08 PCM ZR409 L007-08

53 MODEL MP6.0L PARTS MANUAL - TRANSMISSION AND RELATED COMPONENTS (.0: V - DRIVE) - FIGURE ITEM PART NO. QTY. DESCRIPTION MODEL ID R0400 Fitting, 90 degree R0400 Fitting, 90 degree RA706 Transmission,.0:, (w/r07906 Adapter) 4 RA04007S Hose Assembly, cooler to transmission RA04007T Hose Assembly, transmission to cooler 6 R0400 Fitting, 90 degree 7 R4704 Cooler Assembly, transmission 8 R09000 Clamp, cooler assembly mounting 9 RS04 Bolt, cooler attaching 0 RS078 Nut, cooler attaching RS00 Bolt, cooler clamp attaching R0900A Bracket, cooler mounting RS80 Lockwasher, cooler clamp attaching bolt 4 RS08 Nut, oil cooler clamp attaching bolt R6600 Shift Bracket Arm L PCM ZR409