MARINE ILLUSTRATED PARTS MANUAL

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1 MARINE ILLUSTRATED PARTS MANUAL MODEL MP6.0L MY /04

2 This Page Was Intentially Left Blank

3 MODEL MP6.0L PARTS MANUAL - Contents: Symbols... 2 Maintenance Item Part Numbers... 3 Cylinder Block Assembly - Figure... 4 Cylinder Head Assembly / Front Cover - Figure Exhaust Manifold Assembly / Knock Sensors - Figure Intake Manifold Components - Figure Oil Pan and Oil Pump Assembly - Figure 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 03 (Standard Drive) - Figure Fuel Control Cell (FCC) Components 04 (Standard Drive) - Figure Fuel Control Cell (FCC) Components 03 ( V - Drive) - Figure Fuel Control Cell (FCC) Components 04 ( V - Drive) - Figure Heat Exchanger and Components - Figure Fresh Water Cooling System Components - Figure Raw Water Drain System Components - Figure Exhaust Manifold and Components - Figure Raw Water Cooling Pump - Figure 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 TYPICAL VIEWS ARE SHOWN ENGINE ROTATION 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.)

4 MODEL MP6.0L PARTS MANUAL - 2 HOW TO READ THIS PARTS BOOK: ITEM PART NUMBER DESCRIPTION QUANTITY RB00005I Base Engine Assembly, 6.0L ITEM NUMBER - This number corresponds with the number in the exploded view on the facing page. 2 PART NUMBER - This is the designated part number for the particular component or assembly. 3 DESCRIPTION - This identifi es what the component or assembly is. 4 QUANTITY - This refers to the number of pieces used. ====================================================================== 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 ======================================================================

5 MODEL MP6.0L PARTS MANUAL - 3 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 Fuel Filter (FCC) Spark Plugs Spark Plug Wire Set Serpentine Drive Belt Raw Water Pump Impeller Kit Thermostat Part Number R07700 RP RP0300 RK2002 R RP06022 R 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.

6 MODEL MP6.0L PARTS MANUAL - 4 CYLINDER BLOCK ASSEMBLY - FIGURE PC60P_

7 MODEL MP6.0L PARTS MANUAL - 5 CYLINDER BLOCK ASSEMBLY - FIGURE ITEM PART NUMBER DESCRIPTION QUANTITY * RB0002 Base Engine Assembly TBD Bearing Set, camshaft 2 TBD Bearing Set, connecting rod (STD) 8 3 TBD Piston, (STD) 8 4 TBD Ring Set, piston (STD) 8 5 TBD Connecting Rod (STD) 8 6 TBD Bolt, connecting rod cap 6 7 TBD Bolt, rear engine cover 2 8 RA3806 Flywheel Assembly 9 R Bolt, fl ywheel attaching 6 0 R Seal, crankshaft rear oil TBD Cover, rear engine 2 TBD Gasket, rear engine cover 3 part of item #4 Reluctor Ring, crankshaft 4 TBD Crankshaft Assembly 5 TBD Bearing Set, crankshaft 6 TBD Cap, crankshaft bearing # and #5 2 7 TBD Bolt, crankshaft bearing cap side 0 8 TBD Cap, crankshaft bearing #2 - #4 3 9 TBD Stud, crankshaft bearing cap attaching 20 TBD Bolt, crankshaft bearing cap attaching 2 R06406 Balancer, crankshaft 22 TBD Bolt, crankshaft balancer 23 TBD Oil Pump Assembly 24 TBD Drive, oil pump 25 TBD Key, crankshaft 26 TBD Chain, timing 27 TBD Bolt, camshaft sprocket attaching 28 TBD Sprocket, camshaft 29 TBD Bolt, camshaft retainer attaching 3 30 TBD Retainer, camshaft 3 TBD Camshaft

8 MODEL MP6.0L PARTS MANUAL - 6 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE PC60P_

9 MODEL MP6.0L PARTS MANUAL - 7 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE 2 ITEM PART NUMBER DESCRIPTION QUANTITY TBD Hose, PCV valve 2 TBD Valve, positive crankcase ventilation (PCV) 3 TBD Grommet, PCV valve 4 TBD Rocker Arm, valve 6 5 TBD Bolt, valve rocker arm attaching 6 6 TBD Guide, valve rocker arm 2 7 TBD Valve Spring Assembly 6 8 TBD Retainer, valve stem Bolt, lifting eye attaching Lockwasher, lifting eye attaching bolt 4 R04202 Lifting Eye 2 2 TBD Cap, valve spring 6 3 TBD Seal, valve stem 6 4 TBD Rotator, valve 32 5 TBD Guide, valve stem 6 6 RP0300 Spark Plug 8 7 RK2002 Spark Plug Wire Set 8 R Engine Coolant Temperature (ECT) Sensor 9 TBD Valve, exhaust (STD) 8 20 TBD Valve, intake (STD) 8 2 TBD Bolt, valve lifter retainer attaching 8 22 TBD Retainer, valve lifter 8 23 RM0280 Gasket, front engine cover 24 TBD Cover, front engine 25 R Seal, front engine cover oil 26 RM028 Gasket, water circulating pump 2 27 RA Water Circulation Pump Assembly 28 TBD Bolt, water circulating pump attaching 4 29 RM0275 Gasket, thermostat housing 2 30 R Housing, thermostat Bolt, thermostat housing attaching Lockwasher, thermostat housing attaching Plug, thermostat housing 34 R Thermostat, (60 F) 35 R0905 Plate, thermostat retainer 36 RS355 Plug, water neck 37 R Water Neck 38 R Switch, coolant temperature 39 TBD Bolt, front engine cover attaching 8

10 MODEL MP6.0L PARTS MANUAL - 8 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE 2 (cont d) PC60P_

11 MODEL MP6.0L PARTS MANUAL - 9 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE 2 (cont d) ITEM PART NUMBER DESCRIPTION QUANTITY 40 TBD Lifter, valve 6 4 TBD Push Rod 6 42 RM0278 Gasket, Cylinder Head 2 43 R00306 Cylinder Head 2 44 TBD Bolt, cylinder head (short) 6 45 TBD Bolt, cylinder head (medium) 4 46 TBD Bolt, cylinder head (long) 4 47 TBD Cover, rocker (LH) 48 RM0282 Gasket, rocker cover 2 49 TBD Bolt, rocker cover attaching 8 50 TBD Tube, breather 5 TBD Tube, oil fi ll 52 R034038B Cap, oil fi ll tube 53 TBD Fitting, breather tube 54 TBD Cover, rocker (RH)

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

13 EXHAUST MANIFOLD / KNOCK SENSORS - FIGURE 3 MODEL MP6.0L PARTS MANUAL - ITEM PART NUMBER DESCRIPTION QUANTITY TBD Bolt, coolant air bleed pipe attaching 2 2 TBD Pipe, coolant air bleed 3 TBD Harness, knock sensor 4 TBD Bolt, crankshaft position attaching 5 R Sensor, crankshaft position 6 TBD Bolt, valley cover attaching 0 7 R Sensor, knock 2 8 TBD Cover, valley 9 TBD Gasket, valley cover 0 TBD Seal, knock sensor oil 2 R Sensor, camshaft position 2 TBD Bolt, camshaft position attaching 3 R02906 Elbow, exhaust 2 4 RM0274 Gasket, exhaust elbow to manifold 2 5 R Manifold, exhaust 2 6 R03035 Stud, exhaust manifold attaching Lockwasher, exhaust manifold stud attaching Nut, exhaust manifold stud attaching 2 9 R Switch, exhaust temperature 2

14 MODEL MP6.0L PARTS MANUAL - 2 INTAKE MANIFOLD COMPONENTS - FIGURE PC60P_

15 INTAKE MANIFOLD COMPONENTS - FIGURE 4 MODEL MP6.0L PARTS MANUAL - 3 ITEM PART NUMBER DESCRIPTION QUANTITY R75055 Bolt, engine cover attaching 2 2 R Insert, engine cover 3 R Cover, engine 4 R703 Coil, ignition 8 5 R Bracket, ignition coil mounting 2 6 R Bracket, support 2 7 TBD Bolt, fuel rail attaching 4 8 RK2002 Spark Plug Wire Set 9 R Regulator, fuel pressure ( 03 Only) 0 R Sensor, manifold absolute pressure (MAP) TBD Seal, throttle body 2 R Plate, throttle body adapter 3 RM025 Gasket, throttle body 4 RA035036B Throttle Body Assembly 5 L0098 Nut, throttle body attaching 3 6 R Intake Manifold 7 RA Fuel Injector Assembly 8 8 R27097 Retainer, fuel injector 8 9 RS526 Bolt, coil bracket attaching Bolt, coil bracket attaching 2 NI Lockwasher, coil bracket attaching Bolt, ignition coil attaching 6 22 RM0277 Gasket Set, intake manifold 23 R4354 Decal, engine cover 2 24 R Fuel Rail, 6.0L, (right) 25 R Fuel Rail, 6.0L, w/regulator pocket (left) 25 R086004A Fuel Rail, 6.0L, w/o regulator pocket (left)

16 MODEL MP6.0L PARTS MANUAL - 4 OIL PAN and OIL PUMP ASSEMBLY - FIGURE PC60P_

17 OIL PAN and OIL PUMP ASSEMBLY - FIGURE 5 MODEL MP6.0L PARTS MANUAL - 5 ITEM PART NUMBER DESCRIPTION QUANTITY R04079 Tube, oil dipstick 2 R04080 Dipstick, oil level (0 to 4 degree) AR 2 R0408 Dipstick, oil level (2 degree) AR 3 RS0302 Bolt, oil dipstick tube attaching 4 R2705 Clamp, oil dipstick tube attaching 5 RS280 Lockwasher, oil dipstick tube attaching 6 RS028 Nut, oil dipstick tube attaching 7 TBD Bolt, engine rear cover attaching 8 R Seal, engine rear cover oil 9 TBD Cover, engine rear 0 R Tube, oil pickup RM0279 Gasket, oil pan 2 R Oil Pan 3 TBD Bolt, oil sending unit adapter attaching 2 4 R07907 Adapter, oil sending unit 5 TBD Gasket, oil sending unit adapter 6 TBD Bolt, oil pan attaching (long) 2 7 TBD Bolt, oil pan attaching (short) 2 8 TBD Nut, oil pickup tube attaching 9 TBD Bolt, oil pickup tube attaching 20 TBD Nut, windage tray attaching 0 2 TBD O-ring, oil pickup tube 22 R02027 Tray, windage 23 TBD Bolt, oil pump attaching 4 24 TBD Oil Pump Assembly 25 TBD Drive, oil pump

18 MODEL MP6.0L PARTS MANUAL - 6 THROTTLE BODY and RELATED COMPONENTS - FIGURE PC60P_

19 MODEL MP6.0L PARTS MANUAL - 7 THROTTLE BODY and RELATED COMPONENTS - FIGURE 6 ITEM PART NUMBER DESCRIPTION QUANTITY R45026 Arrestor, fl ame 2 RS3857 Clamp, fl ame arrestor 3 R Bracket, perfect pass 4 R08008 Throttle Arm, throttle body 5 RA035036B Throttle Body Assembly 6 R Valve, idle air control 7 TBD Screw, IAC valve attaching 2 8 TBD Screw, TP sensor attaching 2 9 R02004 Sensor, throttle position 0 R78003 Ball Joint Assembly, cable attaching RS2055 Locking Nut, cable clip mounting bolt 2 2 R090267A Throttle Bracket, intake 3 TBD Bolt, throttle cable brkt attaching 2 4 R Cable Clip, throttle attaching 5 RS522 Bolt, cable clip mounting 2 6 RS078 Nut, throttle arm attaching 2 7 RS025 Bolt, throttle arm attaching Lockwasher, bracket attaching 9 RS6503 Bolt, bracket attaching

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

21 MODEL MP6.0L PARTS MANUAL - 9 REMOTE OIL FILTER COMPONENTS (STANDARD DRIVE) - FIGURE 7 ITEM PART NUMBER DESCRIPTION QUANTITY Bolt, oil fi lter header mounting 3 2 RS279 Lockwasher, oil fi lter header mounting 3 3 R Oil Filter Header 4 R Bracket, oil fi lter header mounting 5 RS540 Nut, sender terminal 6 RS297 Lockwasher, sender terminal 7 R02000 Sender, oil pressure 8 R02445 Tee, sender attaching 9 R02005A Switch, oil pressure 0 R07907 Adapter, oil sending unit R O-ring, oil bypass adapter 2 R Adapter, oil bypass 3 R O-ring, oil bypass adapter attaching fi tting 4 R Nut, oil bypass adapter attaching 5 R02484 Fitting, 90 degree 6 RA04520D Hose Assembly, fi lter header to bypass adapter 7 RA04520D Hose Assembly, bypass adapter to fi lter header 8 R02448 Fitting, straight 9 R07700 Filter, oil 20 R Nipple, header fi lter adapter 2 R O-Ring, oil line 2

22 MODEL MP6.0L PARTS MANUAL - 20 REMOTE OIL FILTER COMPONENTS ( V - DRIVE) - FIGURE PC60P_

23 MODEL MP6.0L PARTS MANUAL - 2 REMOTE OIL FILTER COMPONENTS ( V - DRIVE) - FIGURE 8 ITEM PART NUMBER DESCRIPTION QUANTITY R Bracket, oil fi lter header mounting 2 R Oil Filter Header 3 R Nipple, header fi lter adapter 4 R07700 Filter, oil 5 RS279 Lockwasher, oil fi lter header mounting Bolt, oil fi lter header mounting 3 7 RA04520 Hose Assembly, bypass adapter to fi lter header 8 RA04520 Hose Assembly, fi lter header to bypass adapter 9 R02484 Fitting, 90 degree 2 0 R Fitting, oil bypass adapter attaching R O-ring, oil bypass adapter attaching fi tting 2 R Adapter, oil bypass 3 R O-ring, oil bypass adapter 4 R07907 Adapter, oil sending unit 5 R02005A Switch, oil pressure 6 R02445 Tee, sender attaching 7 R02000 Sender, oil pressure 8 RS297 Lockwasher, sender terminal 9 RS540 Nut, sender terminal 20 R O-Ring, oil line 2

24 MODEL MP6.0L PARTS MANUAL - 22 FUEL CONTROL CELL (FCC) COMPONENTS 2003 (STANDARD DRIVE) - FIGURE a PC60P_

25 MODEL MP6.0L PARTS MANUAL - 23 FUEL CONTROL CELL (FCC) COMPONENTS 2003 (STANDARD DRIVE) - FIGURE 9 ITEM PART NUMBER DESCRIPTION QUANTITY RA03503 Fitting, fuel pressure, Schrader valve NI R03404 Cap, schrader valve 2 R02463A Fitting, fuel line 3 R02475 Fitting, fuel line 3a RA Pump, high pressure fuel 4 R04724 O-ring, FCC sealing 5 RP Filter, FCC fuel (includes O-ring) 6 RA085090C Hose Assembly, FCC to fuel rail (inlet) 7 RA08509C Hose Assembly, fuel rail to FCC (return) Bolt, FCC mounting 3 9 R Bracket, FCC mounting 0 R Fitting, 90 degree RS52L Locking Nut, low-pressure fuel pump 3 2 R09642 Washer, fuel pump mounting 3 3 R094035A Grommet, mounting bracket 3 4 R Bracket, low-pressure fuel pump mounting 5 R0964 Washer, fuel pump mounting 3 6 R Fitting, 90 degree 7 RA08008 Fuel Pump, low-pressure 8 R02492 Fitting, 90 degree 9 RA085070A Hose Assembly, low-pressure pump to FCC 20 RA Fuel Control Cell Assembly NI R432 Decal, FCC operating instructions NI R434 Decal, Warning, fuel leaks 2 R02463 Fitting, 90 degree Bolt, FCC mounting bracket 2 23 RS7070 Lockwasher, FCC mounting bracket Lockwasher, bracket attaching Bolt, bracket attaching

26 MODEL MP6.0L PARTS MANUAL - 24 FUEL CONTROL CELL (FCC) COMPONENTS 2004 (STANDARD DRIVE) - FIGURE PC60P_008a

27 MODEL MP6.0L PARTS MANUAL - 25 FUEL CONTROL CELL (FCC) COMPONENTS 2004 (STANDARD DRIVE) - FIGURE 0 ITEM PART NUMBER DESCRIPTION QUANTITY R02424 Fitting, fuel line 2 R Regulator, fuel pressure ( 04 Only) 3 RA Pump, high pressure fuel 4 R04724 O-ring, FCC sealing 5 RP Filter, FCC fuel (includes O-ring) 6 RA085090C Hose Assembly, FCC to fuel rail (inlet) Bolt, FCC mounting 3 8 R Bracket, FCC mounting 9 R Fitting, 90 degree 0 RS52L Locking Nut, low-pressure fuel pump 3 R09642 Washer, fuel pump mounting 3 2 R094035A Grommet, mounting bracket 3 3 R Bracket, low-pressure fuel pump mounting 4 R0964 Washer, fuel pump mounting 3 5 R Fitting, 90 degree 6 RA08008 Fuel Pump, low-pressure 7 R02492 Fitting, 90 degree 8 RA085070A Hose Assembly, low-pressure pump to FCC 9 RA Fuel Control Cell Assembly NI R432 Decal, FCC operating instructions NI R434 Decal, Warning, fuel leaks 20 R02463 Fitting, 90 degree Bolt, FCC mounting bracket 2 22 RS7070 Lockwasher, FCC mounting bracket Lockwasher, bracket attaching Bolt, bracket attaching

28 MODEL MP6.0L PARTS MANUAL - 26 FUEL CONTROL CELL (FCC) COMPONENTS 2003 ( V - DRIVE) - FIGURE 2 3 3a PC60P_

29 MODEL MP6.0L PARTS MANUAL - 27 FUEL CONTROL CELL (FCC) COMPONENTS 2003 ( V - DRIVE) - FIGURE ITEM PART NUMBER DESCRIPTION QUANTITY RA03503 Fitting, fuel pressure, schrader valve NI R03404 Cap, schrader valve 2 R02463A Fitting, fuel line 3 R02475 Fitting, fuel line 3a RA Pump, high pressure fuel ( 03 Only) 4 R04724 O-ring, FCC sealing 5 RP Filter, FCC fuel (includes O-ring) 6 RA085090B Hose Assembly, FCC to fuel rail (inlet) 7 RA08509B Hose Assembly, fuel rail to FCC (return) Bolt, FCC mounting 3 9 R Bracket, FCC mounting 0 RS7070 Lockwasher, FCC mounting bracket Bolt, FCC mounting bracket 2 2 R Fitting, 90 degree 3 R02463 Fitting, 90 degree 2 4 RA Fuel Control Cell Assembly NI R432 Decal, FCC operating instructions NI R434 Decal, Warning, fuel leaks 5 RA08507B Hose Assembly, low-pressure pump to FCC 6 RS52L Locking Nut, low-pressure fuel pump 3 7 R09642 Washer, fuel pump mounting 3 8 R Grommet, mounting bracket 3 9 R Bracket, low-pressure fuel pump mounting 20 R0964 Washer, fuel pump mounting 3 2 R Fitting, 90 degree 22 RA08008 Fuel Pump, low-pressure Lockwasher, bracket attaching Bolt, bracket attaching

30 MODEL MP6.0L PARTS MANUAL - 28 FUEL CONTROL CELL (FCC) COMPONENTS 2004 ( V - DRIVE) - FIGURE PC60P_03a

31 MODEL MP6.0L PARTS MANUAL - 29 FUEL CONTROL CELL (FCC) COMPONENTS 2004 ( V - DRIVE) - FIGURE 2 ITEM PART NUMBER DESCRIPTION QUANTITY R02424 Fitting, fuel line 2 R Regulator, fuel pressure ( 04 Only) 3 RA Pump, high pressure fuel ( 04 Only) 4 R04724 O-ring, FCC sealing 5 RP Filter, FCC fuel (includes O-ring) 6 RA085090B Hose Assembly, FCC to fuel rail (inlet) Bolt, FCC mounting 3 8 R Bracket, FCC mounting 9 RS7070 Lockwasher, FCC mounting bracket Bolt, FCC mounting bracket 2 R Fitting, 90 degree 2 R02463 Fitting, 90 degree 2 3 RA Fuel Control Cell Assembly NI R432 Decal, FCC operating instructions NI R434 Decal, Warning, fuel leaks 4 RA08507B Hose Assembly, low-pressure pump to FCC 5 RS52L Locking Nut, low-pressure fuel pump 3 6 R09642 Washer, fuel pump mounting 3 7 R Grommet, mounting bracket 3 8 R Bracket, low-pressure fuel pump mounting 9 R0964 Washer, fuel pump mounting 3 20 R Fitting, 90 degree 2 RA08008 Fuel Pump, low-pressure Lockwasher, bracket attaching Bolt, bracket attaching

32 MODEL MP6.0L PARTS MANUAL - 30 HEAT EXCHANGER and COMPONENTS - FIGURE PC60P_

33 HEAT EXCHANGER and COMPONENTS - FIGURE 3 MODEL MP6.0L PARTS MANUAL - 3 ITEM PART NUMBER DESCRIPTION QUANTITY R Cap, degas bottle 2 R4600 Bottle, degas NI R4352 Decal, 6.0L specifi cation NI R4353 Decal, coolant fi ll 3 RS3872 Clamp, hose 2 4 R04553 Hose, degas bottle to heat exchanger 5 R68008 Anode, sacrifi cial zinc AR 6 RS078 Nut, ground wire stud 7 R003 Wire, grounding 8 RA47047 Heat Exchanger Assembly 9 R End Cap Kit, exchanger AR 0 R Isolator, rubber 2 R Bracket, heat exchanger 2 RS0304 Bolt, heat exchanger bracket attaching 2 3 RS2380 Lockwasher, mounting bolt 2 4 RS3857 Clamp, exchanger mounting 2 NI R4355 Decal, Protective Anode NI R4362 Decal, 6.0 Emission MY 03 NI R Decal, 6.0 Emission MY 04 NI R4358 Decal, Ultra Low Emission

34 MODEL MP6.0L PARTS MANUAL - 32 FRESH WATER COOLING SYSTEM COMPONENTS - FIGURE PC60P_

35 MODEL MP6.0L PARTS MANUAL - 33 FRESH WATER COOLING SYSTEM COMPONENTS - FIGURE 4 ITEM PART NUMBER DESCRIPTION QUANTITY R0455 Hose, exchanger to exhaust manifold (Starboard STD) 2 RS3872 Clamp, hose 2 3 R04553 Hose, degas bottle to heat exchanger 4 R Cap, degas bottle 5 R4600 Bottle, degas 6 R27087 Clamp, hose (5/8 - degas bottle) 7 R04532 Hose, coolant air bleed to bottle 8 RS385 Clamp, hose ( ) 4 9 R04549 Hose, circ. pump to heat exchanger 0 RS3868 Clamp, hose ( /2 ) 2 R04548 Hose, exchanger to thermostat housing 2 R04550 Hose, exchanger to exhaust manifold (Port STD) 3 R024006A Fitting, 90 degree 4 R4704 Cooler, transmission oil Plug, manifold 2 6 TBD Tube, coolant air bleed 7 RM028 Gasket, water pump to engine block 2 8 RA Water Pump Assembly 9 RA Raw Water Pump 20 R04559 Hose, oil cooler to raw water pump (level installation with.23: transmission) 20 R04552 Hose, oil cooler to raw water pump (angled installation with.0: transmission) 2 R04547 Hose, raw water pump to exchanger 22 RM0275 Gasket, thermostat housing 2 23 R Thermostat Housing 24 R0905 Plate, thermostat retainer 25 R Thermostat, (60 degree) 26 R Water Neck 27 R04553 Hose, coolant bypass fi tting (3/4 bulk) 28 R02420 Bypass, coolant 29 R Hose, coolant bypass fi tting (5/8 bulk) 30 R Fitting, manifold straight 3 RS3858 Clamp, hose ( /4 ) 6 32 R27087G Clamp, hose ( /6 oetiker) 2 33 R27087F Clamp, hose ( oetiker) 2 34 R27084 Clamp, hose (vent tube)

36 MODEL MP6.0L PARTS MANUAL - 34 OPTIONAL DRAIN KIT COMPONENTS - FIGURE 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.

37 OPTIONAL DRAIN KIT COMPONENTS - FIGURE 5 MODEL MP6.0L PARTS MANUAL - 35 ITEM PART NUMBER DESCRIPTION QUANTITY R02428 Fitting, straight 4 2 R02425 Tee, hose 2 3 RS3557 Plug, drain 4 R02426 Fitting, 4-way RW drain NS R27087G Clamp, hose ( /6 oetiker) 0 NS R27087F Clamp, hose ( oetiker) 2

38 MODEL MP6.0L PARTS MANUAL - 36 EXHAUST MANIFOLD and COMPONENTS - FIGURE PC60P_

39 EXHAUST MANIFOLD and COMPONENTS - FIGURE 6 MODEL MP6.0L PARTS MANUAL - 37 ITEM PART NUMBER DESCRIPTION QUANTITY RS527 Nut, exhaust elbow attaching 8 2 RS279 Lockwasher, exhaust elbow attaching 8 3 RM0274 Gasket, manifold to exhaust elbow 2 4 R03036 Stud, exhaust elbow attaching (short) 4 4 R03039 Stud, exhaust elbow attaching w/4 riser (short) AR 5 R Exhaust Manifold Assembly 2 6 R03035 Stud, manifold to cylinder head attaching 2 7 RS279 Lockwasher, manifold to cylinder head attaching 2 8 RS7026 Nut, manifold to cylinder head attaching 2 9 RM0276 Gasket, manifold to cylinder head 2 0 R02906 Exhaust Elbow Assembly 2 R03037 Stud, exhaust elbow attaching (long) 4 R03040 Stud, exhaust elbow attaching w/4 riser (long) AR 2 R Switch, exhaust temperature 2 3 R09644 Retainer, spark plug wire clip Washer, retainer attaching 2 5 RS0280 Bolt, retainer attaching 2 6 TBD Bolt, bracket attaching Lockwasher, bracket attaching Bolt, bracket attaching 4 9 R Bracket, manifold support 2 20 R43002F Decal, exhaust manifold, 6.0L 2 *NOTE: See Fresh Water Cooling section for parts used on Fresh Water Cooled engines.

40 MODEL MP6.0L PARTS MANUAL - 38 RAW WATER COOLING PUMP - FIGURE PC60P_

41 RAW WATER COOLING PUMP - FIGURE 7 MODEL MP6.0L PARTS MANUAL - 39 ITEM PART NUMBER DESCRIPTION QUANTITY TBD Bolt, bearing housing attaching 3 2 TBD Lockwasher, bearing housing attaching bolt 3 3 R O-ring, bearing housing attaching bolt 3 4 R O-ring, bearing housing attaching 5 RP06022 Impeller 6 R Housing, raw water pump 7 RA3407 Bearing Housing Assembly 8 RA Raw Water Pump Assembly

42 MODEL MP6.0L PARTS MANUAL - 40 WIRING HARNESS ASSEMBLIES and SENDERS - FIGURE PC60P_

43 MODEL MP6.0L PARTS MANUAL - 4 WIRING HARNESS ASSEMBLIES and SENDERS - FIGURE 8 ITEM PART NUMBER DESCRIPTION QUANTITY RS540 Nut, sender terminal 2 RS297 Lockwasher, sender terminal 3 RS2746 Washer, sender terminal 4 R Sender, temperature 5 R02009 Sensor, engine coolant temperature (ECT) 6 RA2076C Engine Wiring Harness Assembly ( 02-04) (MUST be used with relay, p/n R300A) 7 R09642 Washer, main harness attaching 4 8 RS55 Screw, main harness attaching 4 9 RS540 Nut, sender terminal 0 RS297 Lockwasher, sender terminal R02000 Sender, oil pressure 2 R02445 Tee, sender attaching 3 R07907 Adapter, oil sending unit 4 R02005A Switch, oil pressure 5 TBD Harness, ignition coil 2 6 R2078 Harness, FCC ( V - Drive) AR

44 MODEL MP6.0L PARTS MANUAL - 42 ECM and RELAYS - FIGURE a a A / 6A PC60P_

45 ECM and RELAYS - FIGURE 9 MODEL MP6.0L PARTS MANUAL - 43 ITEM PART NUMBER DESCRIPTION QUANTITY R53006C Circuit Breaker Assembly (60 amp) 2 RS5084 Bolt, circuit breaker mounting Bolt, circuit breaker bracket attaching 2 4 R Bracket, circuit breaker mounting NI Decal, main circuit breaker 5 RS0302 Bolt, oil dipstick tube attaching 6 R3002 Relay, fuel pump, ignition, starter 3 (s/n thru 44502) 6A R300A Relay, fuel pump, ignition, starter 3 (s/n thru present) 7 R609K Engine Control Module (MEFI 4) ( 03 Only) 7 R602 Engine Control Module (MEFI 4B) ( 04 Only) Bolt, ECM attaching 3 9 R2604 Cover, fuse holder 0 R5307B Fuses, 20 amp 3 RS0304 Bolt, bracket attaching 2 2 RS280 Lockwasher, bracket attaching bolt 2 3 RS028 Nut, oil dipstick tube attaching 4 RS280 Lockwasher, oil dipstick tube attaching 5 R2705 Clamp, oil dipstick tube attaching 6 R Bracket, ECM/relay mounting

46 MODEL MP6.0L PARTS MANUAL - 44 ACCESSORY DRIVE SYSTEM COMPONENTS - FIGURE 20 Belt Tensioner Alternator Idler Circulation Pump Raw Water Pump Crankshaft Pulley A PC60P_

47 MODEL MP6.0L PARTS MANUAL - 45 ACCESSORY DRIVE SYSTEM COMPONENTS - FIGURE 20 ITEM PART NUMBER DESCRIPTION QUANTITY R Belt, serpentine drive 2 part of item #5 Bolt, tensioner pulley attaching 3 part of item #5 Washer, tensioner pulley attaching bolt 4 part of item #5 Pulley, tensioner 5 RA Tensioner, belt 6 RS653 Bolt, idler pulley attaching 7 RS279 Lockwasher, idler pulley attaching bolt Washer, idler pulley attaching bolt (small) 9 R09645 Washer, idler pulley attaching bolt (large) 0 R Pulley, idler R Bracket, idler pulley mounting / alternator Lockwasher, idler pulley bracket attaching bolt Bolt, idler pulley bracket attaching Bolt, alternator mounting 5 RA Raw Water Pump Assembly Bolt, raw water pump mounting 2 7 R Pulley, raw water pump Flat Washer, raw water pump pulley attaching Lockwasher, raw water pump pulley attaching bolt Bolt, raw water pump pulley attaching 3 2 R06406 Balancer, crankshaft 22 TBD Bolt, crankshaft balancer 23 TBD Bolt, water circulation pump attaching 4 24 TBD Bolt, belt tensioner mounting 3 25 RA097007C Alternator Assembly 26 R Pulley, alternator (70 amp) Flatwasher, alternator mounting Lockwasher, alternator mounting Bolt, alternator mounting 30 R4347 Decal, belt routing

48 MODEL MP6.0L PARTS MANUAL - 46 STARTER ASSEMBLY COMPONENTS - FIGURE PC60P_

49 STARTER ASSEMBLY COMPONENTS - FIGURE 2 MODEL MP6.0L PARTS MANUAL - 47 ITEM PART NUMBER DESCRIPTION QUANTITY RS708 Nut, solenoid terminal 2 RS7080 Lockwasher, solenoid terminal 3 RU0050A Solenoid, starter 4 R Bolt, starter mounting 2 5 RA2209 Starter Motor Assembly Lockwasher, solenoid terminal 2 7 RS7036 Nut, solenoid terminal 2

50 MODEL MP6.0L PARTS MANUAL - 48 ENGINE and TRANSMISSION MOUNTS - FIGURE 22 Engine Mount Group Front Mount Engine Mount Group Rear Mount PC60P_

51 ENGINE and TRANSMISSION MOUNTS - FIGURE 22 MODEL MP6.0L PARTS MANUAL - 49 ITEM PART NUMBER DESCRIPTION QUANTITY R Bolt, trunnion clamp Lockwasher, engine mount attaching bolt Bolt, engine mount attaching 8 4 R Mount, engine front 2 5 RS28 Lockwasher, trunnion clamp bolt 2 6 RS529 Nut, trunnion clamp bolt 2 7 RS075 Nut, adjustment and lock 4 8 RS286 Lockwasher, adjusting nut 2 9 R0900 Trunnion 2 0 RC0900 Trunnion Assembly RA09206 Trunnion Assembly 2 RA0920 Trunnion Assembly, tall (.23: STD / V-drive) 2 Used with item #7 - R09045 mount 2 RA0920A Trunnion Assembly, tall (.23: STD / V-drive) 2 Used with item #6 - R mount 2 RA09003 Trunnion Assembly, short (.0: STD) 2 Used with item #7 - R09045 mount 2 RA09006 Trunnion Assembly, short (.0: STD) 2 Used with item #6 - R mount 3 R09003 Trunnion, 2.5 (use with R09045) 2 3 R09006 Trunnion, 2.25 (use with R090205) 2 4 RS0329 Bolt, rear mount attaching (R090205) 4 4 RS0328 Bolt, rear mount attaching (R09045) 4 5 RS28 Lockwasher, rear mount attaching bolt 4 6 R Mount, rear 7 R09045 Mount, rear 8 R Mount, engine front (port).23: 8 R Mount, engine front (starboard).23: 8 R Mount, engine front (port).0: 8 R Mount, engine front (starboard).0: NI Lockwasher, engine mount attaching bolt 6 NI Bolt, engine mount attaching, upper 4 NI Bolt, engine mount attaching, lower 2

52 MODEL MP6.0L PARTS MANUAL - 50 BELL HOUSING ASSEMBLY - FIGURE a PC60P_

53 BELL HOUSING ASSEMBLY - FIGURE 23 MODEL MP6.0L PARTS MANUAL - 5 ITEM PART NUMBER DESCRIPTION QUANTITY RA5706 Transmission Assembly, (:) AR a R Adapter, V-Drive AR 2 RS28 Lockwasher, transmission attaching bolt 4 3 RS0334 Bolt, transmission attaching 4 4 RA5707 Transmission Assembly, (.23:) AR 5 R4006 Plate, damper (PCM Transmissions) 5 R4008 Plate, damper (Hurth Transmission/2-speed) 6 RS7070 Lockwasher, damper plate attaching bolt Bolt, damper plate attaching 6 8 R090A Cover, dust, (stbd) (use w/top mount starter) 8 R090 Cover, dust (stbd) (use w/bottom mount starter) 9 R0902 Cover, dust (port) 0 RS078 Nut, dust cover attaching 2 RS6503 Bolt, dust cover attaching 2 2 RS0256 Bolt, dust cover attaching 2 3 R03034 Stud, bellhousing attaching 2 4 RS7070 Lockwasher, bellhousing attaching Nut, bellhousing attaching 2 6 RS6556 Bolt, bellhousing attaching 2 7 RS7070 Lockwasher, bellhousing attaching 2 8 R4204A Bellhousing Lockwasher, dust cover attaching 2 NI R0900 Cover, dust, top mount starter (used w/r090) NI RS0327 Bolt, dust cover attaching 2 NI RS28 Lockwasher, dust cover attaching 2

54 MODEL MP6.0L PARTS MANUAL - 52 TRANSMISSION AND RELATED COMPONENTS (STANDARD DRIVE) - FIGURE A - FRONT MOUNT SHIFT BRACKET A PC60P_

55 MODEL MP6.0L PARTS MANUAL - 53 TRANSMISSION AND RELATED COMPONENTS (STANDARD DRIVE) - FIGURE 24 ITEM PART NUMBER DESCRIPTION QUANTITY R Cable Clip, single cable 2 RS522 Bolt, cable clip attaching 2 3 R09043A Bracket, shift 4 RS2055 Nut, cable clip attaching bolt 2 5 R02400 Fitting, 90 degree 6 R Fitting, 45 degree 7 RA5707 Transmission,.23: 7 RA5706 Transmission,.0: AR 8 RA045007B Hose Assembly, cooler to transmission 9 R4704 Transmission Cooler Assembly 0 R02400 Fitting, 90 degree 2 RA045007T Hose Assembly, transmission to cooler

56 MODEL MP6.0L PARTS MANUAL - 54 TRANSMISSION AND RELATED COMPONENTS (.0: V - DRIVE) - FIGURE PCB57036

57 MODEL MP6.0L PARTS MANUAL - 55 TRANSMISSION AND RELATED COMPONENTS (.0: V - DRIVE) - FIGURE 25 ITEM PART NUMBER DESCRIPTION QUANTITY R09000 Bracket, oil cooler mounting 2 R4704 Cooler, oil, transmission 3 R02400 Fitting, 90 degree 4 R02400 Fitting, 90 degree 5 RA5706 Transmission,.0:, (w/r Adapter) 6 RA045007B Hose Assembly, cooler to transmission 2 7 RA045007K Hose Assembly, transmission to cooler 8 R02400 Fitting, 90 degree 2

MARINE ILLUSTRATED PARTS MANUAL MODEL MP6.0L

MARINE ILLUSTRATED PARTS MANUAL MODEL MP6.0L L510014 12/02 This Page Was Intentially Left Blank MODEL MP6.0L PARTS MANUAL - 1 Contents: Symbols... 2 Maintenance Item Part Numbers... 3 Cylinder Block Assembly