MARINE ILLUSTRATED PARTS MANUAL

MARINE ILLUSTRATED PARTS MANUAL MODEL MP6.0L MY 2003-2004 09/04

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MODEL MP6.0L PARTS MANUAL - Contents: Symbols... 2 Maintenance Item Part Numbers... 3 Cylinder Block Assembly - Figure... 4 Cylinder Head Assembly / Front Cover - Figure 2... 6 Exhaust Manifold Assembly / Knock Sensors - Figure 3... 0 Intake Manifold Components - Figure 4... 2 Oil Pan and Oil Pump Assembly - Figure 5... 4 Throttle Body Assemblies and Related Components - Figure 6... 5 Remote Oil Filter Components (Standard Drive) - Figure 7... 6 Remote Oil Filter Components ( V - Drive) - Figure 8... 20 Fuel Control Cell (FCC) Components 03 (Standard Drive) - Figure 9... 22 Fuel Control Cell (FCC) Components 04 (Standard Drive) - Figure 0... 24 Fuel Control Cell (FCC) Components 03 ( V - Drive) - Figure... 26 Fuel Control Cell (FCC) Components 04 ( V - Drive) - Figure 2... 28 Heat Exchanger and Components - Figure 3... 30 Fresh Water Cooling System Components - Figure 4... 32 Raw Water Drain System Components - Figure 5... 34 Exhaust Manifold and Components - Figure 6... 36 Raw Water Cooling Pump - Figure 7... 38 Wiring Harness Assemblies and Senders - Figure 8... 40 ECM and Relays - Figure 9... 42 Accessory Drive System Components - Figure 20... 44 Starter Assembly Components - Figure 2... 46 Engine and Transmission Mounts - Figure 22... 48 Bellhousing Assembly - Figure 23... 50 Transmission and Related Parts (Standard Drive) - Figure 24... 52 Transmission and Related Parts ( V - Drive) - Figure 25... 54 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.)

MODEL MP6.0L PARTS MANUAL - 2 HOW TO READ THIS PARTS BOOK: ITEM PART NUMBER DESCRIPTION QUANTITY RB00005I Base Engine Assembly, 6.0L 2 3 4 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 ======================================================================

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 RP080026 RP0300 RK2002 R066027 RP06022 R026007 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.

MODEL MP6.0L PARTS MANUAL - 4 CYLINDER BLOCK ASSEMBLY - FIGURE 4 3 2 6 5 27 29 3 7 8 9 30 26 28 5 0 25 3 2 23 24 4 5 22 2 6 7 6 8 20 9 PC60P_00-4-02

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 R009205 Bolt, fl ywheel attaching 6 0 R047236 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

MODEL MP6.0L PARTS MANUAL - 6 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE 2 33 34 35 3 32 30 36 29 28 52 5 37 38 27 50 26 9 39 53 0 25 54 24 23 49 40 48 42 4 43 22 47 2 2 3 44 45 20 4 9 5 46 6 7 6 8 5 8 3 4 2 9 0 7 PC60P_004 0-2-02

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 32 9 98443025 Bolt, lifting eye attaching 4 0 93940000 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 R020046 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 R047237 Seal, front engine cover oil 26 RM028 Gasket, water circulating pump 2 27 RA057033 Water Circulation Pump Assembly 28 TBD Bolt, water circulating pump attaching 4 29 RM0275 Gasket, thermostat housing 2 30 R025036 Housing, thermostat 3 9822306 Bolt, thermostat housing attaching 2 32 93920000 Lockwasher, thermostat housing attaching 2 33 386 Plug, thermostat housing 34 R026002 Thermostat, (60 F) 35 R0905 Plate, thermostat retainer 36 RS355 Plug, water neck 37 R024208 Water Neck 38 R020002 Switch, coolant temperature 39 TBD Bolt, front engine cover attaching 8

MODEL MP6.0L PARTS MANUAL - 8 CYLINDER HEAD ASSEMBLY / FRONT COVER - FIGURE 2 (cont d) 33 34 35 3 32 30 36 29 28 52 5 37 38 27 50 26 9 39 53 0 25 54 24 23 49 40 48 42 4 43 22 47 2 2 3 44 45 20 4 9 5 46 6 7 6 8 5 8 3 4 2 9 0 7 PC60P_004 0-2-02

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)

MODEL MP6.0L PARTS MANUAL - 0 EXHAUST MANIFOLD / KNOCK SENSORS - FIGURE 3 2 3 6 7 8 2 9 9 3 4 5 0 4 5 6 7 8 PC60P_005 8-29-03

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 R020044 Sensor, crankshaft position 6 TBD Bolt, valley cover attaching 0 7 R020043 Sensor, knock 2 8 TBD Cover, valley 9 TBD Gasket, valley cover 0 TBD Seal, knock sensor oil 2 R020045 Sensor, camshaft position 2 TBD Bolt, camshaft position attaching 3 R02906 Elbow, exhaust 2 4 RM0274 Gasket, exhaust elbow to manifold 2 5 R028023 Manifold, exhaust 2 6 R03035 Stud, exhaust manifold attaching 2 7 93930000 Lockwasher, exhaust manifold stud attaching 2 8 97330000 Nut, exhaust manifold stud attaching 2 9 R020047 Switch, exhaust temperature 2

MODEL MP6.0L PARTS MANUAL - 2 INTAKE MANIFOLD COMPONENTS - FIGURE 4 2 23 3 4 5 9 2 20 6 7 24 25 9 8 8 0 7 6 5 4 3 2 22 PC60P_009 9-2-03

INTAKE MANIFOLD COMPONENTS - FIGURE 4 MODEL MP6.0L PARTS MANUAL - 3 ITEM PART NUMBER DESCRIPTION QUANTITY R75055 Bolt, engine cover attaching 2 2 R060063 Insert, engine cover 3 R060062 Cover, engine 4 R703 Coil, ignition 8 5 R090273 Bracket, ignition coil mounting 2 6 R090268 Bracket, support 2 7 TBD Bolt, fuel rail attaching 4 8 RK2002 Spark Plug Wire Set 9 R088003 Regulator, fuel pressure ( 03 Only) 0 R020036 Sensor, manifold absolute pressure (MAP) TBD Seal, throttle body 2 R062087 Plate, throttle body adapter 3 RM025 Gasket, throttle body 4 RA035036B Throttle Body Assembly 5 L0098 Nut, throttle body attaching 3 6 R002025 Intake Manifold 7 RA087008 Fuel Injector Assembly 8 8 R27097 Retainer, fuel injector 8 9 RS526 Bolt, coil bracket attaching 2 20 9822306 Bolt, coil bracket attaching 2 NI 93920000 Lockwasher, coil bracket attaching 2 2 907075 Bolt, ignition coil attaching 6 22 RM0277 Gasket Set, intake manifold 23 R4354 Decal, engine cover 2 24 R086003 Fuel Rail, 6.0L, (right) 25 R086004 Fuel Rail, 6.0L, w/regulator pocket (left) 25 R086004A Fuel Rail, 6.0L, w/o regulator pocket (left)

MODEL MP6.0L PARTS MANUAL - 4 OIL PAN and OIL PUMP ASSEMBLY - FIGURE 5 2 3 4 5 6 7 8 9 24 25 23 22 2 20 0 9 8 2 7 6 5 4 3 PC60P_002-7-02

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 R047236 Seal, engine rear cover oil 9 TBD Cover, engine rear 0 R074030 Tube, oil pickup RM0279 Gasket, oil pan 2 R005025 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

MODEL MP6.0L PARTS MANUAL - 6 THROTTLE BODY and RELATED COMPONENTS - FIGURE 6 2 9 8 3 4 7 5 6 7 6 5 4 3 2 9 8 0 PC60P_00 9-2-03

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 R090278 Bracket, perfect pass 4 R08008 Throttle Arm, throttle body 5 RA035036B Throttle Body Assembly 6 R084003 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 R090086 Cable Clip, throttle attaching 5 RS522 Bolt, cable clip mounting 2 6 RS078 Nut, throttle arm attaching 2 7 RS025 Bolt, throttle arm attaching 2 8 93920000 Lockwasher, bracket attaching 9 RS6503 Bolt, bracket attaching

MODEL MP6.0L PARTS MANUAL - 8 REMOTE OIL FILTER COMPONENTS (STANDARD DRIVE) - FIGURE 7 4 2 2 3 5 6 7 20 8 9 9 0 8 3 2 7 4 5 6 PC60P_04-8-02

MODEL MP6.0L PARTS MANUAL - 9 REMOTE OIL FILTER COMPONENTS (STANDARD DRIVE) - FIGURE 7 ITEM PART NUMBER DESCRIPTION QUANTITY 99333020 Bolt, oil fi lter header mounting 3 2 RS279 Lockwasher, oil fi lter header mounting 3 3 R079066 Oil Filter Header 4 R090275 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 R047240 O-ring, oil bypass adapter 2 R079067 Adapter, oil bypass 3 R047202 O-ring, oil bypass adapter attaching fi tting 4 R079068 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 R024203 Nipple, header fi lter adapter 2 R047245 O-Ring, oil line 2

MODEL MP6.0L PARTS MANUAL - 20 REMOTE OIL FILTER COMPONENTS ( V - DRIVE) - FIGURE 8 20 2 3 4 5 6 9 8 7 5 6 4 3 2 0 7 9 8 PC60P_05-7-02

MODEL MP6.0L PARTS MANUAL - 2 REMOTE OIL FILTER COMPONENTS ( V - DRIVE) - FIGURE 8 ITEM PART NUMBER DESCRIPTION QUANTITY R090275 Bracket, oil fi lter header mounting 2 R079066 Oil Filter Header 3 R024203 Nipple, header fi lter adapter 4 R07700 Filter, oil 5 RS279 Lockwasher, oil fi lter header mounting 3 6 99333020 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 R079068 Fitting, oil bypass adapter attaching R047202 O-ring, oil bypass adapter attaching fi tting 2 R079067 Adapter, oil bypass 3 R047240 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 R047245 O-Ring, oil line 2

MODEL MP6.0L PARTS MANUAL - 22 FUEL CONTROL CELL (FCC) COMPONENTS 2003 (STANDARD DRIVE) - FIGURE 9 2 3 3a 6 4 7 5 8 9 22 23 2 0 2 3 4 24 25 20 9 5 6 8 7 PC60P_008 8-29-03

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 RA080027 Pump, high pressure fuel 4 R04724 O-ring, FCC sealing 5 RP080026 Filter, FCC fuel (includes O-ring) 6 RA085090C Hose Assembly, FCC to fuel rail (inlet) 7 RA08509C Hose Assembly, fuel rail to FCC (return) 8 90384075 Bolt, FCC mounting 3 9 R090276 Bracket, FCC mounting 0 R024089 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 R090280 Bracket, low-pressure fuel pump mounting 5 R0964 Washer, fuel pump mounting 3 6 R024089 Fitting, 90 degree 7 RA08008 Fuel Pump, low-pressure 8 R02492 Fitting, 90 degree 9 RA085070A Hose Assembly, low-pressure pump to FCC 20 RA080029 Fuel Control Cell Assembly NI R432 Decal, FCC operating instructions NI R434 Decal, Warning, fuel leaks 2 R02463 Fitting, 90 degree 22 98443025 Bolt, FCC mounting bracket 2 23 RS7070 Lockwasher, FCC mounting bracket 2 24 93940000 Lockwasher, bracket attaching 25 98443025 Bolt, bracket attaching

MODEL MP6.0L PARTS MANUAL - 24 FUEL CONTROL CELL (FCC) COMPONENTS 2004 (STANDARD DRIVE) - FIGURE 0 2 3 4 6 5 7 8 2 22 20 9 0 2 3 23 24 9 8 4 5 7 6 PC60P_008a 8-29-03

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 R088004 Regulator, fuel pressure ( 04 Only) 3 RA080027 Pump, high pressure fuel 4 R04724 O-ring, FCC sealing 5 RP080026 Filter, FCC fuel (includes O-ring) 6 RA085090C Hose Assembly, FCC to fuel rail (inlet) 7 90384075 Bolt, FCC mounting 3 8 R090276 Bracket, FCC mounting 9 R024089 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 R090286 Bracket, low-pressure fuel pump mounting 4 R0964 Washer, fuel pump mounting 3 5 R024089 Fitting, 90 degree 6 RA08008 Fuel Pump, low-pressure 7 R02492 Fitting, 90 degree 8 RA085070A Hose Assembly, low-pressure pump to FCC 9 RA080030 Fuel Control Cell Assembly NI R432 Decal, FCC operating instructions NI R434 Decal, Warning, fuel leaks 20 R02463 Fitting, 90 degree 2 98443025 Bolt, FCC mounting bracket 2 22 RS7070 Lockwasher, FCC mounting bracket 2 23 93940000 Lockwasher, bracket attaching 24 98443025 Bolt, bracket attaching

MODEL MP6.0L PARTS MANUAL - 26 FUEL CONTROL CELL (FCC) COMPONENTS 2003 ( V - DRIVE) - FIGURE 2 3 3a 6 4 5 7 8 9 0 2 3 6 7 8 4 9 5 20 2 23 24 3 22 PC60P_03 8-29-03

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 RA080027 Pump, high pressure fuel ( 03 Only) 4 R04724 O-ring, FCC sealing 5 RP080026 Filter, FCC fuel (includes O-ring) 6 RA085090B Hose Assembly, FCC to fuel rail (inlet) 7 RA08509B Hose Assembly, fuel rail to FCC (return) 8 90384075 Bolt, FCC mounting 3 9 R090277 Bracket, FCC mounting 0 RS7070 Lockwasher, FCC mounting bracket 2 98443025 Bolt, FCC mounting bracket 2 2 R024089 Fitting, 90 degree 3 R02463 Fitting, 90 degree 2 4 RA080029 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 R094035 Grommet, mounting bracket 3 9 R090280 Bracket, low-pressure fuel pump mounting 20 R0964 Washer, fuel pump mounting 3 2 R024089 Fitting, 90 degree 22 RA08008 Fuel Pump, low-pressure 23 93940000 Lockwasher, bracket attaching 24 98443025 Bolt, bracket attaching

MODEL MP6.0L PARTS MANUAL - 28 FUEL CONTROL CELL (FCC) COMPONENTS 2004 ( V - DRIVE) - FIGURE 2 2 3 4 5 6 7 8 9 0 2 5 6 7 3 8 4 9 20 22 23 2 2 PC60P_03a 8-29-03

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 R088004 Regulator, fuel pressure ( 04 Only) 3 RA080027 Pump, high pressure fuel ( 04 Only) 4 R04724 O-ring, FCC sealing 5 RP080026 Filter, FCC fuel (includes O-ring) 6 RA085090B Hose Assembly, FCC to fuel rail (inlet) 7 90384075 Bolt, FCC mounting 3 8 R090277 Bracket, FCC mounting 9 RS7070 Lockwasher, FCC mounting bracket 2 0 98443025 Bolt, FCC mounting bracket 2 R024089 Fitting, 90 degree 2 R02463 Fitting, 90 degree 2 3 RA080030 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 R094035 Grommet, mounting bracket 3 8 R090286 Bracket, low-pressure fuel pump mounting 9 R0964 Washer, fuel pump mounting 3 20 R024089 Fitting, 90 degree 2 RA08008 Fuel Pump, low-pressure 22 93940000 Lockwasher, bracket attaching 23 98443025 Bolt, bracket attaching

MODEL MP6.0L PARTS MANUAL - 30 HEAT EXCHANGER and COMPONENTS - FIGURE 3 2 3 4 5 6 7 8 4 9 0 2 3 PC60P_007 2-9-02

HEAT EXCHANGER and COMPONENTS - FIGURE 3 MODEL MP6.0L PARTS MANUAL - 3 ITEM PART NUMBER DESCRIPTION QUANTITY R034045 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 R034034 End Cap Kit, exchanger AR 0 R094040 Isolator, rubber 2 R090279 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 R4362-04 Decal, 6.0 Emission MY 04 NI R4358 Decal, Ultra Low Emission

MODEL MP6.0L PARTS MANUAL - 32 FRESH WATER COOLING SYSTEM COMPONENTS - FIGURE 4 28 32 27 33 29 5 23 25 2 24 30 0 8 3 26 22 3 8 34 8 6 7 9 3 4 5 6 2 3 2 9 0 5 20 3 8 3 7 4 2 8 3 PC60P_006 8-29-03

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 R034045 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 5 386 Plug, manifold 2 6 TBD Tube, coolant air bleed 7 RM028 Gasket, water pump to engine block 2 8 RA057033 Water Pump Assembly 9 RA057032 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 R025036 Thermostat Housing 24 R0905 Plate, thermostat retainer 25 R026002 Thermostat, (60 degree) 26 R024208 Water Neck 27 R04553 Hose, coolant bypass fi tting (3/4 bulk) 28 R02420 Bypass, coolant 29 R045086 Hose, coolant bypass fi tting (5/8 bulk) 30 R024073 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)

MODEL MP6.0L PARTS MANUAL - 34 OPTIONAL DRAIN KIT COMPONENTS - FIGURE 5 2 4 2 3 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.

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

MODEL MP6.0L PARTS MANUAL - 36 EXHAUST MANIFOLD and COMPONENTS - FIGURE 6 2 2 9 0 2 8 7 6 3 4 5 9 20 4 6 5 7 3 8 PC60P_0 2-8-03

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 R028023 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 R020047 Switch, exhaust temperature 2 3 R09644 Retainer, spark plug wire clip 2 4 922200020 Washer, retainer attaching 2 5 RS0280 Bolt, retainer attaching 2 6 TBD Bolt, bracket attaching 2 7 93920000 Lockwasher, bracket attaching 4 8 9065063 Bolt, bracket attaching 4 9 R090305 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.

MODEL MP6.0L PARTS MANUAL - 38 RAW WATER COOLING PUMP - FIGURE 7 6 5 2 4 3 7 8 PC60P_022 9-2-03

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 R047243 O-ring, bearing housing attaching bolt 3 4 R047242 O-ring, bearing housing attaching 5 RP06022 Impeller 6 R057032 Housing, raw water pump 7 RA3407 Bearing Housing Assembly 8 RA057032 Raw Water Pump Assembly

MODEL MP6.0L PARTS MANUAL - 40 WIRING HARNESS ASSEMBLIES and SENDERS - FIGURE 8 3 5 4 6 24 6 7 8 5 9 0 2 3 2 5 4 4 3 PC60P_023-2-02

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 R020002 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

MODEL MP6.0L PARTS MANUAL - 42 ECM and RELAYS - FIGURE 9 30 86 86 87 87a 85 85 87a 87 30 6 6A 2 3 6 / 6A 4 5 7 8 6 9 5 0 4 2 3 PC60P_07-7-02

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 2 3 907075 Bolt, circuit breaker bracket attaching 2 4 R090274 Bracket, circuit breaker mounting NI 23655 Decal, main circuit breaker 5 RS0302 Bolt, oil dipstick tube attaching 6 R3002 Relay, fuel pump, ignition, starter 3 (s/n 420000 thru 44502) 6A R300A Relay, fuel pump, ignition, starter 3 (s/n 44503 thru present) 7 R609K Engine Control Module (MEFI 4) ( 03 Only) 7 R602 Engine Control Module (MEFI 4B) ( 04 Only) 8 907075 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 R090279 Bracket, ECM/relay mounting

MODEL MP6.0L PARTS MANUAL - 44 ACCESSORY DRIVE SYSTEM COMPONENTS - FIGURE 20 Belt Tensioner Alternator Idler Circulation Pump Raw Water Pump Crankshaft Pulley A 2 3 4 24 5 22 6 7 9 2 8 0 3 7 2 4 5 2 20 9 25 6 30 8 20 9 26 27 28 29 PC60P_02 9-2-03

MODEL MP6.0L PARTS MANUAL - 45 ACCESSORY DRIVE SYSTEM COMPONENTS - FIGURE 20 ITEM PART NUMBER DESCRIPTION QUANTITY R066027 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 RA068002 Tensioner, belt 6 RS653 Bolt, idler pulley attaching 7 RS279 Lockwasher, idler pulley attaching bolt 8 92940000 Washer, idler pulley attaching bolt (small) 9 R09645 Washer, idler pulley attaching bolt (large) 0 R065040 Pulley, idler R090269 Bracket, idler pulley mounting / alternator 2 93940000 Lockwasher, idler pulley bracket attaching bolt 2 3 984430 Bolt, idler pulley bracket attaching 4 98446070 Bolt, alternator mounting 5 RA057032 Raw Water Pump Assembly 6 98442030 Bolt, raw water pump mounting 2 7 R065050 Pulley, raw water pump 8 92934000 Flat Washer, raw water pump pulley attaching 3 9 93934000 Lockwasher, raw water pump pulley attaching bolt 3 20 9933506 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 R065055 Pulley, alternator (70 amp) 27 92930000 Flatwasher, alternator mounting 28 93930000 Lockwasher, alternator mounting 29 98339070 Bolt, alternator mounting 30 R4347 Decal, belt routing

MODEL MP6.0L PARTS MANUAL - 46 STARTER ASSEMBLY COMPONENTS - FIGURE 2 2 3 7 6 5 4 PC60P_06-8-02

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 R009203 Bolt, starter mounting 2 5 RA2209 Starter Motor Assembly 6 93003000 Lockwasher, solenoid terminal 2 7 RS7036 Nut, solenoid terminal 2

MODEL MP6.0L PARTS MANUAL - 48 ENGINE and TRANSMISSION MOUNTS - FIGURE 22 Engine Mount Group Front Mount 7 8 5 6 9 4 7 2 3 8 0 Engine Mount Group Rear Mount 6 6 5 5 4 2 7 7 3 PC60P_09 9-2-03

ENGINE and TRANSMISSION MOUNTS - FIGURE 22 MODEL MP6.0L PARTS MANUAL - 49 ITEM PART NUMBER DESCRIPTION QUANTITY R095020 Bolt, trunnion clamp 2 2 93940000 Lockwasher, engine mount attaching bolt 8 3 98443030 Bolt, engine mount attaching 8 4 R090242 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 - R090205 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 - R090205 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 R090205 Mount, rear 7 R09045 Mount, rear 8 R090293 Mount, engine front (port).23: 8 R090294 Mount, engine front (starboard).23: 8 R090302 Mount, engine front (port).0: 8 R090303 Mount, engine front (starboard).0: NI 93940000 Lockwasher, engine mount attaching bolt 6 NI 98443030 Bolt, engine mount attaching, upper 4 NI 98449055 Bolt, engine mount attaching, lower 2

MODEL MP6.0L PARTS MANUAL - 50 BELL HOUSING ASSEMBLY - FIGURE 23 2 3 7 6 a 8 3 4 5 8 2 9 0 9 4 2 3 6 7 5 PC60P_02 2-9-02

BELL HOUSING ASSEMBLY - FIGURE 23 MODEL MP6.0L PARTS MANUAL - 5 ITEM PART NUMBER DESCRIPTION QUANTITY RA5706 Transmission Assembly, (:) AR a R079056 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 6 7 98446030 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 2 5 97440000 Nut, bellhousing attaching 2 6 RS6556 Bolt, bellhousing attaching 2 7 RS7070 Lockwasher, bellhousing attaching 2 8 R4204A Bellhousing 9 93920000 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

MODEL MP6.0L PARTS MANUAL - 52 TRANSMISSION AND RELATED COMPONENTS (STANDARD DRIVE) - FIGURE 24 2 3 4 5 A - FRONT MOUNT SHIFT BRACKET A 7 6 0 8 9 PC60P_08-8-02

MODEL MP6.0L PARTS MANUAL - 53 TRANSMISSION AND RELATED COMPONENTS (STANDARD DRIVE) - FIGURE 24 ITEM PART NUMBER DESCRIPTION QUANTITY R090086 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 R024053 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

MODEL MP6.0L PARTS MANUAL - 54 TRANSMISSION AND RELATED COMPONENTS (.0: V - DRIVE) - FIGURE 25 2 8 7 3 6 5 4 PCB57036

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/r079056 Adapter) 6 RA045007B Hose Assembly, cooler to transmission 2 7 RA045007K Hose Assembly, transmission to cooler 8 R02400 Fitting, 90 degree 2