MARINE ILLUSTRATED PARTS MANUAL - PCM Engines

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MARINEILLUSTRATEDPARTS MANUALMODEL MP5.0/5.7LMY 2002 - 2005L51001305/07

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MODEL MP5.0/5.7L PARTS MANUAL - 1Contents:Symbols . 2Maintenance Item Part Numbers . 3Cylinder Block Assembly - Figure 1 . 4Cylinder Head Assembly - Figure 2 . 8Intake Manifold Assembly - Figure 3 . 10Intake Manifold Components - Figure 4 . 12Oil Pan and Oil Pump Assembly - Figure 5 . 14Throttle Body and Related Components - Figure 6 . 16Remote Oil Filter Components (‘02-’03) DIRECT DRIVE - Figure 7 . 18Remote Oil Filter Components (‘02-’04) V-DRIVE - Figure 8 . 20Remote Oil Filter Components (‘02-’03) - Figure 9 . 22Remote Oil Filter Components (‘04) DIRECT DRIVE - Figure 10 . 24Fuel Control Cell (FCC) Components (‘02-’03) DIRECT DRIVE - Figure 11 . 26Fuel Control Cell (FCC) Components (‘02-’03) DIRECT DRIVE - Figure 12 . 28Fuel Control Cell (FCC) Components (‘05) - Figure 13 . 30Fuel Control Cell (FCC) Components (‘02-’03) V-DRIVE - Figure 14 . 32Fuel Control Cell (FCC) Components (‘04) V-DRIVE - Figure 15 . 34Fuel Control Cell (FCC) Components (‘05) V-DRIVE - Figure 16 . 36Heat Exchanger and Components (‘02-’03) - Figure 17 . 38Heat Exchanger and Components (‘04) - Figure 18 . 40Fresh Water Cooling System Components (Crank-Driven RWP) - Figure 19 . 42Fresh Water Cooling System Components (Belt-Driven RWP) - Figure 20 . 44Fresh Water Cooling System Components (Serpentine RWP) - Figure 21 . 46Raw Water Cooling System Components (Belt-Driven RWP) - Figure 22 . 48Raw Water Cooling System Components (Crank-Driven RWP) - Figure 23 . 50Raw Water Cooling System Components (Serpentine RWP) - Figure 24 . 52Exhaust Manifold and Components - Figure 25 . 54Raw Water Cooling Pump (Belt-Driven) - Figure 26 . 56Raw Water Cooling Pump (Crank-Driven) - Figure 27 . 58Raw Water Cooling Pump (Serpentine) - Figure 28 . 60Wiring Harness Assemblies and Senders - Figure 29 . 62ECM and Relays - Figure 30 . 64Accessory Drive System Components (Belt-Driven RWP) - Figure 31 . 66Accessory Drive System Components (Crank-Driven RWP) - Figure 32 . 70Accessory Drive System Components (Serpentine RWP) - Figure 33 . 72Starter Assembly Components - Figure 34 . 74Engine and Transmission Mounts - Figure 35 . 76Bellhousing Assembly - Figure 36 . 78Transmission and Related Parts (1.23:1 FWC) - Figure 37 . 80Transmission and Related Parts (1.23:1 RWC) - Figure 38 . 82Transmission and Related Parts (1:1 V-Drive) - Figure 39 . 84PRO SPORT / EXCALIBURL510013

MODEL MP5.0/5.7L PARTS MANUAL - 2“TYPICAL VIEWS ARE SHOWN”ENGINE ROTATIONEngine Rotation is identified as “RH” or “LH” with the engine model number. Rotation always is determinedfrom the flywheel end looking toward the front of the engine. In some instances, propeller shaft rotation maybe opposite to that of the engine.When ordering a replacement engine, production block or parts for the engine, be certain to check enginerotation. DO NOT rely on propeller rotation in order to determine engine rotation.LEFT-HAND ROTATION is STANDARD ROTATION.(Flywheel turns counterclockwise when viewed from flywheel end of the engine.)RIGHT-HAND ROTATION is OPPOSITE ROTATION.(Flywheel turns clockwise when viewed from flywheel end of the engine.)HOW TO READ THIS PARTS BOOK:ITEMPART NUMBER1RB001005I12DESCRIPTIONQUANTITYBase Engine Assembly, 5.7L1341ITEM NUMBER - This number corresponds with the number in the exploded view on the facing page.2PART NUMBER - This is the designated part number for the particular component or assembly.3DESCRIPTION - This identifies what the component or assembly is.4QUANTITY - This refers to the number of pieces used. Symbols shown throughout parts list are defined here or on the bottom of the individual parts list page.AR As RequiredOPT OptionalNSS Not Serviced SeparatelyNA Not AvailableOS OversizeUS UndersizeNS Not ShownTBD To Be DeterminedNI Not Illustrated L510013PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 3REPLACEMENT PARTS:WARNING:Electrical, ignition and fuel system components on PCM Engines are designed and manufactured to complywith U.S. Coast Guard rules and regulations to minimize risks of fire or explosion.Use of replacement electrical, ignition and fuel system components which do not comply with these rules andregulations could result in a fire or explosion hazard and should be avoided.MAINTENANCE ITEM PART NUMBERS:DescriptionOil FilterKit, Transmission Oil Filter (ZF)Fuel Filter (FCC)Spark PlugsSpark Plug Wire SetAlternator Drive Belt (V-belt applications)Raw Water Pump Drive Belt (Belt-Driven Pump)Drive Belt Set, (5.0/5.7L)Serpentine BeltImpeller Kit (Belt or Crank Driven Raw Water Pump)Impeller Kit (Serpentine Raw Water Pump)Oil Drain KitExhaust Service Kit, 5.0/5.7LPart 9RP173091MARINE TRANSMISSIONS:PCM Engines are equipped with PCM or Hurth Transmissions, standard or “V”-drives. If transmission partsare required, contact your dealer or closest PCM Parts Distributor for required parts.Parts manuals and overhaul manuals are available through PCM Distributors.PRO SPORT / EXCALIBURL510013

58L510013575944564555465434473548364337384932 DO NOTREMOVE1582413612316117171092218211920MODEL MP5.0/5.7L PARTS MANUAL - 4CYLINDER BLOCK ASSEMBLY - FIGURE 1PC57B01112PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 5CYLINDER BLOCK ASSEMBLY - FIGURE 1ITEMPART DTBDNSSTBDTBDTBDTBDR056001PRO SPORT / EXCALIBURDESCRIPTION5.0L Base Engine Assembly5.7L Base Engine AssemblyRing Set, piston 5.7L (STD)Ring Set, piston 5.0L (STD)Piston, 5.7L (STD)Piston, 5.0L (STD)Bolt, connecting rod capConnecting Rod (STD)Bearing Set, connecting rod (STD)Nut, connecting rod capLifter, valveGuide, valve lifterPlug, camshaftPlug, oil galleryAdapter, oil bypassPlug, engine block coolant drain holeBearing, crankshaft rear main (STD)Bearing, crankshaft rear main (.001 US)Bearing, crankshaft rear main (.010 US)Bearing, crankshaft rear main (.020 US)Pin, flywheel locatingGasket, crankshaft rear oil seal housingHousing, crankshaft rear oil sealBolt, crankshaft rear oil seal housing, shortBolt, crankshaft rear oil seal housing, longSeal, crankshaft rear oilFlywheel Assembly (Top Mount Starter)Flywheel Assembly (Bottom Mount Starter)Bolt, flywheel attachingNut, crankshaft rear oil seal housingStud, crankshaft rear oil seal housingStud, crankshaft rear oil seal housingCap, crankshaft bearing #5Stud, crankshaft bearing capBolt, crankshaft bearing capCap, crankshaft bearing #1 - #4Bearing, crankshaft main (STD)Bearing, crankshaft main (.002 US)Bearing, crankshaft main (.010 US)Bearing, crankshaft main (.020 US)Ring, crankshaft position sensor 2215544ARARAR1L510013

58L510013575944564555465434473548364337384932 DO NOTREMOVE1582413612316117171092218211920MODEL MP5.0/5.7L PARTS MANUAL - 6CYLINDER BLOCK ASSEMBLY - FIGURE 1 (cont’d)PC57B01112PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 7CYLINDER BLOCK ASSEMBLY - FIGURE 1 (cont’d)ITEMPART 006017AR069066PRO SPORT / EXCALIBURDESCRIPTIONCover, engine front cover (includes gasketand seal) ‘02-’03 enginesSensor, crankshaft positionBolt, crankshaft position sensor attachingBearing Set, crankshaft main (STD)Bolt, crankshaft balancerWasher, crankshaft balancer boltBalancer, crankshaft - ‘02 and newerBalancer, crankshaft - ‘97-’01Seal, crankshaft front oilBolt, engine front cover attaching, shortBolt, engine front cover attaching, longGasket, engine front coverSprocket, crankshaftKey, crankshaft balancerBearing Set, camshaftCam Bearing #1Cam Bearing #2 & #5Cam Bearing #3 & #4Pin, camshaft sprocket locatingBolt, camshaft sprocket attachingChain, camshaft timingSprocket, camshaftBolt, camshaft retainingRetainer, camshaftCamshaft, enginePlug, oil galleryBlock, engineRetainer, valve lifterBolt, valve lifter retainerGasket, water pump to engine blockWater Pump AssemblyStud, water pump attachingBolt, water pump attachingBolt, water pump attachingStud, water pump attachingSensor, knockCrankshaft, 350 1996/LaterPlug, Brass, block 1 8L510013

MODEL MP5.0/5.7L PARTS MANUAL - 8CYLINDER HEAD ASSEMBLY - FIGURE 233341XXXX XXXXXX 18182020191820202020CYLINDER HEADBOLT POSITIONPC57B009L510013PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 9CYLINDER HEAD ASSEMBLY - FIGURE 2ITEMPART NUMBERDESCRIPTIONQUANTITY1R143137Decal, oil fill riser cap12R034037Cap, oil fill riser13R034048Riser, oil fill14R024013CElbow, breather tube15R094002Grommet, breather tube elbow16R127098Retainer, oil fill riser17R047228O-ring, oil fill riser18R033008ACover, rocker (left side)19TBDWasher, rocker cover retaining bolt810TBDBolt, rocker cover retaining811R035015Valve, positive crankcase ventilation112R094015Grommet, pcv valve113RM0193Gasket, rocker cover214R049012Retainer, valve stem3215R049015Cap, valve spring1616R046050Valve Spring Assembly1617R047238Seal, valve stem (intake)817R047239Seal, valve stem (exhaust)818R009168Bolt, cylinder head to engine block (long)1419TBDBolt, cylinder head to engine block (medium)420TBDBolt, cylinder head to engine block (short)1621R030010Spark Plug822R043035Valve, (intake)823R043036Valve, (exhaust)824RM0195Gasket, cylinder head225R003007B5.0L Cylinder Head Assembly225R003008B5.7L Cylinder Head Assembly226R09503426Stud, valve rocker arm16TBDStud, valve rocker arm (.013 OS)AR26R095035Stud, valve rocker arm (.033 OS)AR27R039023Push Rod1628R038015Rocker Arm, Assembly w/ball1629R038011Ball, rocker arm1630R017069Nut, rocker arm attaching1631R033008Cover, rocker (right side)132NSSO-Ring, oil fill riser cap133TBDTube, breather134TBDTube, PCV135R042008Bracket, lift ring, front and rear235R042015Bracket, lift ring (front, replaces R042008)136RS0304Bolt, lift ring attaching337RS2180Lockwasher, lift ring attaching338R042014Bracket, lift ring (rear, replaces R042008)1PRO SPORT / EXCALIBURL510013

MODEL MP5.0/5.7L PARTS MANUAL - 10INTAKE MANIFOLD ASSEMBLY - FIGURE 3133302925OR29262728PC57B010L510013PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 11INTAKE MANIFOLD ASSEMBLY - FIGURE 3ITEMPART NUMBER1RA0350402NSS3DESCRIPTIONQUANTITYThrottle Body Assembly1Washer, throttle body attaching stud3R095040Stud, throttle body attaching34R088002Regulator, fuel pressure15TBDRetainer, fuel pressure regulator16R095041Stud, fuel rail attaching47RA086002Fuel Rail Assembly18TBDCap, fuel pressure service port19NSSO-Ring, fuel injector (top)810TBDClip, fuel injector retaining811NSSO-Ring, fuel injector (bottom)812RA087007Fuel Injector Assembly813R085074AHose, fuel pressure regulator vacuum114R095041Stud, MAP sensor attaching115R020039Sensor, manifold absolute pressure116RK120018Spark Plug Wire Set117RM0271Gasket, upper intake manifold to lower118RA108009Cap, distributor119NSSPlate, component attaching220TBDBolt, component attaching plate attaching421R127026AHold Down, distributor122R009193Bolt, distributor hold down123R103011Rotor, distributor124RA107044Distributor Assembly (LH)125RM0123Gasket, distributor assembly126R002023Intake Manifold, lower127R069069Plug, intake manifold128RM0250Gasket, intake manifold229R020003Sender, temperature (FWC)129444705Plug, 1/2” NPT, hex socket, Brass (RWC)130RS2746Washer, sender terminal131RS2197Lockwasher, sender terminal132RS1540Nut, sender terminal133R020019Sensor, engine coolant temperature134R002024Intake Manifold, upper135TBDBolt, upper intake manifold to lower attaching836RM0272Gasket, throttle body to upper manifold137RA120018Coil Wire, Ignition (red)1PRO SPORT / EXCALIBURL510013

MODEL MP5.0/5.7L PARTS MANUAL - 9131318141733133AINTAKE MANIFOLD COMPONENTS - FIGURE 4PC57B008 05L510013PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 13INTAKE MANIFOLD COMPONENTS - FIGURE 4ITEMPART 43159APRO SPORT / EXCALIBURDESCRIPTIONNut, engine cover attachingCover, engine (Grey)Cover, engine (Red)Cover, engine (Red, w/insert, MY ‘05)Cover, engine (Black)Cover, engine (Grey)Cover, engine (Red)Cover, engine (Red, w/insert, MY ‘05)Insert, cover, engine (Black) (MY’05)Ignition Coil/Module AssemblyBracket, ignition coil/module assembly mountingNut, attachingStud, flame arrestor/engine cover attachingWasher, ECM attachingBolt, ECM attachingWasher, attachingBolt, attachingEngine Control ModuleRelay Assembly (S/N 420000 thru 440611)Relay Assembly (S/N 440612 and above)Bolt, circuit breaker mountingBolt, bracket attachingLockwasher, bracket attachingCircuit Breaker Assembly (60 amp)Bracket, ECM/relay mountingFuses, 20 ampCover, fuse holderThrottle Arm, throttle bodyNut, throttle arm attachingBolt, throttle arm attachingBall Joint Assembly, cable attachingLocking Nut, cable clip mounting boltThrottle Bracket, intakeAttaching Clip, throttle cableBolt, cable clip mountingFlame ArrestorDecal, hood, front (5.7L PCM)Decal, hood, front (5.7L PCM) (MY’05)Decal, hood, side (5.7L PCM)Decal, hood, side (5.7L PCM) (MY ‘05)Decal, hood, front (Sea Maxx)Decal, hood, front (5.0L PCM)Decal, hood, side (Sea Maxx)Decal, hood, side (5.0L PCM)Decal, Spec, hood (5.7L, PCM)Decal, Spec, hood (5.0L, PCM)Decal, “Ultra Low Emissions”Decal, 5.7L Emission (C.A.R.B.) MY ‘03Decal, 5.7L Emission (C.A.R.B.) MY ‘04Decal, 5.7L Emission (C.A.R.B.) MY 1221121111111L510013

MODEL MP5.0/5.7L PARTS MANUAL - 14OIL PAN and OIL PUMP ASSEMBLY - FIGURE 51"V" Drive Application L510013PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 15OIL PAN and OIL PUMP ASSEMBLY - FIGURE 5ITEMPART NUMBER1R0580542TBD3DESCRIPTIONQUANTITYShaft, oil pump drive1Retainer, oil pump drive shaft1R022022Pin, oil pump locating24RA070010Oil Pump Assembly15R024066Fitting, oil pan drain hose16R012028Deflector, crankshaft oil17TBDBolt, oil pump18RM0249Gasket, oil pan19R005011Oil Pan110RM0245Gasket, oil pan drain hose fitting111R045049Hose, oil pan drain112TBDReinforcement, oil pan (LH)11395200010Nut, oil pan414R009157Bolt, oil pan1415TBDReinforcement, oil pan (RH)116R024179Fitting, oil pan drain hose117RS3552Plug, oil pan drain hose fitting118TBDNut, crankshaft oil deflector519R041065Tube, oil level dipstick119R041066Tube, oil level dipstick (V-drive)AR20R041036ADipstick, oil level (0 to 4 degree)AR20R041043ADipstick, oil level (12 degree)AR20R041067ADipstick, v-driveAR21RS0302Bolt, dipstick tube mounting clampAR22R090233Bracket, dipstick tubeAR23R127015Clamp, dipstick tube mountingAR24RS1028Nut, dipstick tube mounting clamp boltARNIRK024179PRO SPORT / EXCALIBURKit, oil drain (includes items 5,10,11,16,17)1L510013

MODEL MP5.0/5.7L PARTS MANUAL - 16THROTTLE BODY and RELATED COMPONENTS - FIGURE 612363457817161591413111210PC57B023L510013PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 17THROTTLE BODY and RELATED COMPONENTS - FIGURE 6ITEMPART e Body Assembly1Valve, idle air control1TBDWasher, attaching44TBDScrew, IAC valve attaching25TBDScrew, TP sensor attaching26R020041Sensor, throttle position17RS0251Bolt, throttle arm attaching28RS1078Nut, throttle arm attaching29R081007Throttle Arm, throttle body110R178003Ball Joint Assembly, cable attaching111RS2055Locking Nut, cable clip mounting bolt212R090248Throttle Bracket, intake113R090086Cable Clip, throttle attaching114RS5122Bolt, cable clip mounting215R090261Bracket, perfect pass11698223016Lockwasher, bracket attaching21793920000Bolt, bracket attaching2PRO SPORT / EXCALIBURL510013

MODEL MP5.0/5.7L PARTS MANUAL - 18REMOTE OIL FILTER COMPONENTS (‘02-’04) DIRECT DRIVE - FIGURE 7(Thru ‘04 Model Year S/N - B022L510013PRO SPORT / EXCALIBUR

MODEL MP5.0/5.7L PARTS MANUAL - 19REMOTE OIL FILTER COMPONENTS (‘02-’04) DIRECT DRIVE - FIGURE 7(Thru ‘04

MODEL MP5.0/5.7L PARTS MANUAL - 5 PRO SPORT / EXCALIBUR L510013 ITEM PART NUMBER DESCRIPTION QUANTITY * RB001004B 5.0L Base Engine Assembly * RB001005I 5.7L Base Engine Assembly 1 R015013 Ring Set, piston 5.7L (STD) 8 1 R015006 Ring Set, piston 5.0L (STD) 8 2 RA013016 Piston, 5.7L (STD) 8 2 RA013017 Piston, 5.0L (STD) 8 3 TBD Bolt, connecting rod cap 16

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