2004
Fresh Water
Cooling Installation
Instructions V-Drive
Kit RK147050A

L591002

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Intentially
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L591002TABLE OF CONTENTS
1 - FWC Kit Installation Instructions - V-Drive .................................................................................
Table of Contents ...................................... ........................................................................................... 1
Installation Notes and Recommendations ........................................................................................... 2
Figure 1-1, Parts Deleted, Raw Water System, V-Drive ................................................................... 3-6
Figure 1-2, Parts Added, Raw Water System, V-Drive ................................................................. 7-10
FWC Kit Installation, V-Drive Systems ....................................................................................... 11-21
2 - Fresh Water Cooling Water Flow Diagram ................................................................................. 22

L591002
RK147050A

1

FWC KIT INSTALLATION INSTRUCTIONS - RK147050A
INSTALLATION NOTES AND
RECOMMENDATIONSPCM Technical Support, Warranty and Dealer
Assistance:••••

WARNING

Phone: (803) 345-0050
Fax: (800) 321-3797
E-mail: mschneider@pleasurecraft.com
E-mail: dsoutherland@pleasurecraft.com

REFERENCES:
L510013

Marine Illustrated Parts Manual Model
MP5.0/5.7L MY 2002 - 2004

L510010-04

Owner’s Operation and Maintenance
ManualFire and Explosion Hazard - Gasoline is extremely
flammable and highly explosive, and, if ignited,
can cause serious bodily injury or death. Carefulinspection of the entire fuel system including, but
not limited to, fuel tanks, fuel lines, fuel filters andall fittings is mandatory, especially after periods ofstorage. Replace any component that shows signs ofleakage, corrosion, deterioration, swelling, hardening
or softening.

WARNINGNOTE: Use pipe sealant with Teflon on all fittings
being installed during these procedures. Loctite™ 565,
PST Pipe Sealant, Part No. 56541 or equivalent isrecommended.

WARNING
Do not remove cooling system filler cap whenthe engine is hot. Allow the engine to cool andthen remove the pressure cap slowly, allowing thepressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns.

WARNING
Visually inspect unit for fuel leaks before operating
the engine. If fuel leaks are present, DO NOT operate
the engine, repair immediately.

V-DRIVE INSTALLATION
Installation of the fresh water cooling system on V-drive
applications will require relocation of both the lowpressure fuel pump and the FCC, and servicing of
the high pressure and return fuel lines. To complete
the installation procedure you will require a fuel gauge
equipped with a pressure release valve, an approved
container to vent gasoline into, and the proper tools forreleasing the fuel lines from the fuel rails. Provisions
should be made to recover any fuel spilled. Observe
all safety warnings and cautions when working on thefuel system.

2

Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline
is extremely flammable and highly explosive undercertain conditions. Be sure the ignition key is off anddo not smoke, or allow open flame in the area whileservicing. Wipe up any spilled fuel immediately.

WARNING
Make sure that there are no fuel leaks before closing
the engine hatch.

L591002
RK147050AFIGURE 1-1 5.7L, SERPENTINE, V-DRIVE - R/W

1
5
17

10

3

2

7

16

11

15
12

6

17

18

18
8

13

14

9

4

19
22

20
21
24

L591002
RK147050A

3

FIGURE 1-1 (cont.) 5.7L, SERPENTINE, V-DRIVE - R/W

31

32

26

27 28
25

34 35

29

33

30

37 38

4

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RK147050A

36

PARTS DELETED - 5.7L, SERPENTINE, V-DRIVE - R/W
FIGURE 1-1
ITEMPART NUMBER

DESCRIPTION

1

R045160

Hose, r/w pump to tstat housing

1

2

RS3858Clamp, 1 1/4”

2

3R025031

Housing, tstat, lower

1

4

RM0121

Gasket, tstat housing, lower

1

5

R026002

Thermostat, 160º F

1

6

RM0258Gasket, tstat housing, upper

1

7

R025033

Housing, tstat, upper

1

898333080

Bolt, tstat housing

29RS2179Lock Washer, tstat housing

2

1098223035

Bolt, tstat housing

11193920000

Lock Washer, tstat housing

1

12

R020002

Sender, water temperature

1

13

TBD

Plug, intake, (water temp sender)

1

14

TBD

Plug, bypass, circulating pump

1

15

R045048

Hose, r/w supply to engine

1

16RS3852

Clamp, 1 3/4”

2

17R045107

Hose, r/w dump

218RS3851

Clamp, 1”

4

19R060060

Hood

1

20

R143141

Decal, hood, “PCM Excalibur”

1

21

R143142

Decal, hood, “Excalibur”

2

22

R143143

Decal, hood, spec

1

23(NS)

R143158

Decal, hood, “3 Star” emission

1

24

R128001C

Cover, hose clamp tip (black)8

25

R090204

Bracket, FCC/LPFP

1

26

R143114

Decal, “WARNING” FCC/LPFP Brkt

1

27

RS0304

Bolt, brkt, FCC/LPFP

3

28

RS2180

Lock Washer, brkt, FCC/LPFP

329

RA085090B

Fuel Line, HP supply to rail

1

30

RA085091B

Fuel Line, HP return from rail

1

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RK147050A

QUANTITY

5PARTS DELETED - 5.7L, SERPENTINE, V-DRIVE - R/W
FIGURE 1-1

6

ITEM

PART NUMBER

DESCRIPTION

31

R096144A

Bracket, plug wire clip

1

32

R096144

Bracket, plug wire clip

1

33

R090233

Bracket, dipstick tube clip

1

34

RS0302

Bolt, dipstick tube clip, retaining

1

35

RS1028Nut, dipstick tube clip, retaining

1

36

R127015

Clamp, dipstick tube

1

37

RS0304

Bolt, bell housing attaching

1

38

RS2180

Lock Washer, bell housing attaching1

L591002
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QUANTITYFIGURE 1-2 5.7L, SERPENTINE, V-DRIVE - F/W
19 20 2122

19 20 21

18

10

9
30

8
29
26

28

4

14
6

5

25

7

16

12

17

13

15

2
1

31

34

32

33

36

L591002
RK147050A

7

FIGURE 1-2 (cont.) 5.7L, SERPENTINE, V-DRIVE - F/W
25

24
27
23
16
26
17

11
54

9

55
12

45

29
61
30

13

30

52

57

56

46

50
51

47

58

60

59

63
53

65
64
40 41

49
48

42 43 44

37

8

45

3
1

39

38

35

46

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62

PARTS ADDED - 5.7L, SERPENTINE, V-DRIVE -F/W
FIGURE 1-2
ITEMPART NUMBER

DESCRIPTION

1

R045146

Hose, f/w supply, circ. pump to H.E.

1

2

RS3852

Clamp, 1 3/4”

13RS3868Clamp, 1 1/2”

1

4R025015A

Housing, water neck outlet

1

5

RM0121

Gasket, water neck outlet

1

6

RS6531

Bolt, water neck outlet

2

793200000

Lock Washer, water neck outlet

2

8

R024055

Elbow, 1/8 NPT X 1/4 vent hose

1

9

R045144

Hose, f/w return, H.E. to water neck1

10RS3858Clamp, 1 1/4”

111RS3868Clamp, 1 1/2”

1

12

R045163

Hose, r/w supply, r/w pump to H.E.

1

13RS3858Clamp, 1 1/4”

2

14R020003

Sender, water temperature

1

15

R024217

Fitting, circ. pump, bypass

1

16

R045086

Hose, bypass, 5/8” X 31”

1

17

RS3864

Clamp, 5/8”

2

18R090295

Bracket, degas bottle

1

1998223016

Bolt, brkt, degas bottle

2

20

RS2672

Lock Washer, brkt, degas bottle

2

21

RS7068Flat Washer, brkt, degas bottle

2

22

R146001

Degas Bottle

1

23

R034045

Cap, degas bottle

1

24

R143166

Decal, bottle, top, “Open Slowly”

1

25

R143153

Decal, bottle, side, “Engine Coolant Fill”

1

26

R045132

Hose, coolant vent, 1/4” X 30”

1

27

R127087

Clamp, Oetiker

1

28RS3870Clamp, 1/4”

1

29

R045164

Hose, f/w fill130

RS3854

Clamp, 3/4”

2

31R060061B

Hood

1

32

R143141

Decal, hood, “PCM Excalibur”

1

33

R143142

Decal, hood, “Excalibur”

2

34

R143143

Decal, hood, spec

1

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RK147050A

QUANTITY

9PARTS ADDED - 5.7L, SERPENTINE, V-DRIVE -F/W
FIGURE 1-2

10

ITEM

PART NUMBER

DESCRIPTION

35

R128001C

Cover, hose clamp tip (black)

20

36

R127015

Clamp, Dipstick tube

1

37

R090299

Bracket, low pressure fuel pump

1

38

R090296

Bracket, FCC

1

39(NS)

R143114

Decal, “WARNING” FCC brkt

1

40

RS0305Bolt, brkt, FCC

1

41

RS2180

Lock Washer, brkt, FCC

1

42

RS0283

Bolt, brkt, FCC

1

43

RS2158Lock Washer, brkt, FCC

1

44

RS1027Nut, brkt, FCC

1

45

RA085090B

Fuel Line, high pressure supply to rail

1

46

RA085091B

Fuel Line, HP return from rail

1

47

R090266

Bracket, heat exchanger

1

48

RS0304

Bolt, brkt, heat exchanger

2

49

RS2180

Lock Washer, brkt, heat exchanger

2

50

R094040

Isolator, rubber, adhesive

1

51

RA147050

Heat Exchanger

1

52

R094041

Isolator, rubber

2

53

RS3857

Clamp, 4”2

54R025039

Thermostat Housing

1

55

R026007

Thermostat, 170° F

1

56

R045162

Hose, tstat housing to H.E., 2 1/2”

157(NS)

R143155

Decal, “Protective Anode”

1

58(NS)

R143156

Decal, “Raw Water Drain”

1

59(NS)

R143157

Decal, “Fresh Water Drain”

1

60

R143158

Decal, “3 Star” emission

1

61

RS3860Clamp, 2 1/2”

2

62

R045151

Hose, r/w dump, 1”

2

63

RS3851

Clamp, 1”

4

64

R101013

Wire, H.E. ground1

65

RS1078Nut, w/lock washer, H.E. grd. stud1

L591002
RK147050A

QUANTITYFWC KIT INSTALLATION INSTRUCTIONS - V-DRIVEFWC KIT INSTALLATION - V-DRIVEREMOVEWIRE
TEMP
SENDER

1. Disconnect the negative battery terminal cable.
2. Remove the hood (Figure 1-1, item 19) from theengine. The hood is not required to complete
the installation. Save the hood retention nuts
for installation of the new hood later in thisprocedure.

REMOVECLAMP

REMOVE
CLAMPSREMOVE
CLAMP

3. Remove the thermostat housing, watertemperature sender, and associated hoses.
NOTE: The complete thermostat housing with hoses,
temp sender, and thermostat can be remove as an
assembly. (Figure1-1, items 1-18)

Figure 1-3 Disconnect Points - Steps 3a, 3b.
a. Disconnect the wire connected to
the water temperature sender (Figure
1-1, item 12), located in the lower
thermostat housing.
b. Loosen the hose clamps of the raw
water dump hoses at each exhaust
manifold connection, the raw water
pump hose at the raw water pump, andthe raw water supply to engine hose at
the circulating pump. Refer to Figure
1-3.
IMPORTANT: Some V-drive applications route theoutput of the raw water pump to the V-drive
gear instead of going to the t-stat housing. Do
not disconnect the hose at the raw water pump.
Instead disconnect the raw water supply hose at thethermostat and continue with this procedure.

INTAKE
MANIFOLD
PLUG

T-STAT
HOUSING
BOLTS

CIRC.
PUMP
PLUG

Figure 1-4 Disconnect Points - Steps 3c, 4, 5.

c. Remove the two bolts and lockwashers (Figure 1-4) attaching thethermostat housing assembly to theintake manifold.
d. Remove, from the engine, thethermostat assembly, all hoses andclamps. Clean thermostat gasket fromthe intake manifold. None of theseparts are required to complete theinstallation. Refer to Figure 1-5.
4. Remove and discard the plug located top, centerof the circulating pump. Refer to Figure 1-4.
5. Remove and discard the plug located right, frontof the intake manifold. Refer to Figure 1-4.

L591002
RK147050A

Figure 1-5 Parts removed - Steps 3-5.

11

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
NOTE: Use pipe sealant with Teflon on all fittings
being installed during these procedures. Loctite™ 565,
PST Pipe Sealant, Part No. 56541 or equivalent isrecommended.
6. From the kit, install the Bypass Fitting (Figure
1-2, item 15) into the circulating pump, where theplug was removed.
7. From the kit, install the Water Temperature
Sender (Figure 1-2, item 14) into the intake
manifold, where the plug was removed, andreconnect the temperature sending wire to thesensor. This is the wire disconnected in step 3a.

DEGAS
BOTTLE
MOUNT

8. Remove 90° hose fittings from the (engine) frontof each exhaust manifold and the plug fitting fromthe rear of each exhaust manifold.
Install the hose fittings in the (engine) rear ofeach exhaust manifold, with the hose barb facing
inboard. Install the plugs in the front of eachexhaust manifold.

Figure 1-6 Degas Bottle Bracket Mounting Location

9. From the kit, install the Degas Bottle Bracket
using (2) Bolts (*metric), (2) Lock washers, and(2) Flat washers (Figure 1-2, items 18-21). The
bracket is installed to the existing bracket on the(engine) starboard side of the intake manifold.
10. From the kit, install the Water Neck Outlet using(2) Bolts, (2) Lock washers, and Gasket (Figure
1-2, items 4-7), provided.
11. From the kit, install the Vent Hose Fitting (Figure
1-2, item 8) into the Water Neck Outlet. The
hose barb should be positioned to starboard,
approximately parallel with the Water Neck
Outlet.
12. From the kit, install the Fresh Water Supply
Hose (Figure 1-2, item 1) to the circulating pumpusing 1-3/4” Hose Clamp (Figure 1-2, item 2).
The F/W Supply Hose will route to the rear of theengine along the lower starboard side, below theexhaust manifold.

F/W
RETURNHOSE

R/W
SUPPLY
HOSE

WATER
TEMP
SENDERVENT
HOSE &FITTING

BYPASSHOSE &FITTINGF/W
SUPPLY
HOSE

Figure 1-7 Hose and Fitting Locations

12

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
13. From the kit, install the Fresh Water Return
Hose (Figure 1-2, item 9) to the Water Neck
Outlet using 1-1/4” Hose Clamp (Figure 1-2, item10). The F/W Return Hose will route to the rearof the engine along the top, starboard side of theengine, inside of the oil fill, and outside of theDegas Bottle Bracket installed in step 12. The
open end of the hose will point to the port sideof the engine.

F/W
RETURNHOSE

R/W
SUPPLY
HOSE

WATER
TEMP
SENDER

14. From the kit, install the Bypass Hose, 5/8” X 31”,
(Figure 1-2, item 16), onto the Bypass Fitting
on the circulating pump, using 5/8” Hose Clamp(Figure 1-2, item 17). This hose will route up
and to the rear of the engine on the port side of
the throttle body.
15. From the kit, install the Raw Water Supply Hose,(Figure 1-2, item 12) 90° end, to the raw water
pump using 1-1/4” Hose Clamp (Figure 1-2, item13). This hose will route to the rear of the engine
along the top port side of the intake manifold.

VENT
HOSE &FITTING

BYPASSHOSE &FITTINGF/W
SUPPLY
HOSE

Figure 1-8 Hose and Fitting Locations

IMPORTANT: If your V-drive application routes theoutput of the raw water pump directly to the V-drive
gear unit; you will not use the Raw Water Supply
Hose supplied in the kit.
16. From the kit, obtain the Degas Bottle, Degas
Bottle Cap, “Open Slowly” Decal, “Engine
Coolant Fill” Decal, Coolant Vent Hose (1/4” X30”), Fresh Water Fill Hose, 1/4” Oetiker Hose
Clamp, 1/4” Hose Clamp, and 3/4” Hose Clamp(Figure 1-2, items 23-30).
a. The cap end of the degas bottle isthe front of the degas bottle. On
the upper starboard, forward, outside
corner of the degas bottle, above the“MIN”/”MAX” marks, affix the “Engine
Coolant Fill” Decal here. Affix the“Open Slowly” decal just behind the
cap.

VENT
HOSE
ATTACHED

DEGAS
BOTTLECAP

DEGAS
BOTTLEDECALS

Figure 1-9 Degas Bottle Assemblyb. Attach the Coolant Vent Hose to the
top nipple fitting on the degas bottle
using the 1/4” Oetiker Hose Clamp.

L591002
RK147050A

13

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
c. Attach the Fresh Water Fill Hose to thebottom hose outlet of the degas bottle.
d. Install the Degas Bottle Cap on the
Degas Bottle. With the cap towards
the front of the engine, route the
Coolant Vent Hose down and under
the Degas bottle so the end of thehose is toward the front of the engine.
Route the vent hose inside of the oil
fill and attach it to the Vent HoseFitting on the Water neck Outlet using
1/4” Hose Clamp. (Figure 1-2, item 28)
Seat the Degas Bottle on the Degas
Bottle Bracket.
17. Remove and save the stud bolt in the upper
center position of the bell housing. This will
release a ground wire and the main engine
harness 10-pin connector bracket. Relocate the
10-pin connector bracket to the lower bolt that
attaches the top mount starter block off plate.
Refer to Figure 1-10.

NEW LOCATIONGROUND WIRE
REUSE WIRE CLIP BOLTHEAT EXCHANGERGROUND WIRE AND
FCC BRKT LOCATIONGROUND STUD,GROUND WIRE
10-PIN BRACKET

10-PIN BRACKETRELOCATED TO
LOWER PLATE BOLT

Figure 1-10 FWC V-Drive Contact Points - Rear

18. Remove the starboard plug wire retaining clip
bracket. Discard the plug wire bracket, thedipstick tube bracket, dipstick tube retaining
clamp, and the dipstick tube retaining clamp
mounting bolt and nut. Use the mounting bolt
and lock washer to attach the ground wire (step17) to the lower inboard hole on the starboard
head. Be sure to remove the paint from aroundthe mounting hole so that a good ground isachieved. Reinstall the stud bolt (step 17) backinto the upper center hole of the bell housing.
Refer to Figure 1-10.
19. From the kit, install the new dipstick tube
retaining clamp (Figure 1-2, item 36) onto thedipstick tube. Gently rotate the dipstick tube
outboard. Remove the engine’s rear most
exhaust manifold retaining bolt. Position thedipstick tube clip mounting hole so the exhaust
manifold bolt will pass through the clip and into
the exhaust manifold mounting hole. Tighten theexhaust manifold bolt securely. Refer to Figure
1-11.

Figure 1-11 FWC V-Drive - Dipstick Tube
Relocated

20. Disconnect electrical connections to the FCC
and LPFP fuel pumps.

14

DIPSTICK
TUBE
LOCATION

L591002
RK147050A

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVEWARNING
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline
is extremely flammable and highly explosive undercertain conditions. Be sure the ignition key is off anddo not smoke or allow open flame in the area whileservicing. Wipe up any spilled fuel immediately.
21. At the schrader valve located on the fuel rail, use
the appropriate tool and approved container tobleed fuel pressure from the fuel lines. Release
the fuel line retaining clips from both thehigh pressure and return fuel lines, at thefuel rail. Using the appropriate tool, release
both lines from the fuel rail. Fuel lines willcontain some residual fuel, take appropriate
measures to minimize fuel spillage. Remove
both the HP supply and HP return fuel lines fromthe FCC and discard. Refer Figure 1-12.

HP
SUPPLY
FUEL LINE

FUEL
LINE
RETAINERHP
RETURNFUEL LINE

SCHRADER
VALVE

22. Disconnect the fuel tank return line from the
FCC. Keep line elevated and use appropriate
measures to minimize fuel leakage.
23. Disconnect the fuel tank supply line from the
LPFP. Keep line elevated and use appropriate
measures to minimize fuel leakage.

Figure 1-12 FWC Service Points - Fuel Lines - Top

24. Remove (3) bolts and (3) lock washers securing
the FCC/LPFP bracket to the port head of theengine. Remove bracket with FCC and LPFP
attached and set aside.
NOTE: The bracket, bracket attaching bolts andwashers, and spark plug wire clip bracket will not bereused. The FCC, FCC attaching hardware, and fuelfittings will be reused in later steps, as will the LPFP with
its associated hardware.
IMPORTANT: The FCC and LPFP will contain fuel,make sure they are temporarily stored in an uprightposition so fuel will not spill from them.

WARNING
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline
is extremely flammable and highly explosive undercertain conditions. Be sure the ignition key is off anddo not smoke or allow open flame in the area whileservicing. Wipe up any spilled fuel immediately.

L591002
RK147050A

15

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVEWARNING
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline
is extremely flammable and highly explosive undercertain conditions. Be sure the ignition key is off anddo not smoke or allow open flame in the area whileservicing. Wipe up any spilled fuel immediately.
25. Remove the upper engine port side bell housing
bolt and lock washer. There will be a groundwire attached at this point. Discard the bolt andlock washer. Refer to Figure 1-13.
26. From the kit, locate the FCC Bracket, FCC
brkt. mounting bolt and lock washer, FCC
brkt. mounting bolt, lock washer, and nut, H.E.
Ground wire. (Figure 1-2, items 38, 40-44, 66)
Attach the FCC Bracket to the bell housing
starting with the outboard mounting hole using
the bolt, lock washer, and nut (do not tighten).
Rotate the FCC bracket inboard to align thebracket’s slot with the bell housing’s mounting
hole where the ground wire was attached. To
ensure a good ground, make sure the paintis cleaned from around both sides of the FCC
bracket mounting slot and the bell housing
mounting hole. Using the bolt and lock washer,
attach the H.E. ground wire, engine ground wireand FCC bracket to the bell housing. Tighten
FCC Bracket mounting bolts.

NEW LOCATIONGROUND WIRE
REUSE WIRE CLIP BOLTHEAT EXCHANGERGROUND WIRE AND
FCC BRKT LOCATIONGROUND STUD,GROUND WIRE
10-PIN BRACKET

10-PIN BRACKETRELOCATED TO
LOWER PLATE BOLT

Figure 1-13 FCC Bracket and Ground LocationsHEAT
EXCHANGER
BRACKETNOTE: Engine harness will be routed behind (engineside) the FCC Bracket, the Remote Oil Lines are routed
in front (gear side) of the FCC Bracket.
27. From the kit, cut the rubber isolator withadhesive into thirds. Affix the isolator onto
the Heat Exchanger Bracket in the center andinboard of each of the mounting clamp holes.

HEAT EXCHANGERBRACKET MOUNTINGLOCATION

28. From the kit, mount the Heat Exchanger Bracket
to the bell housing using (2) bolts and (2) lockwashers. (Figure 1-2, items 49-51)
NOTE: The Remote Oil Lines will route behind (engineside) the H.E. Bracket.
29. From the kit, obtain the Heat Exchanger,
Thermostat housing, Thermostat, Thermostat
Housing to Heat Exchanger Hose, and (2) 2-1/2”
Hose Clamps. (Figure 1-2, items 53-58,63)
Install the Thermostat into the Heat Exchanger
with the spring portion of the Thermostat facing
up. Place the Tstat Housing to H.E. Hose overthe H.E. fitting with the (2) hose clamps in place
but not tight. (Continued on next page.)

16

L591002
RK147050A

Figure 1-14 Heat Exchanger Bracket Location

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
29. (cont.) Seat the Thermostat Housing into thehose, making sure that it contacts the thermostat
and fits into the collar of the H.E. fitting. The
Tstat Housing Bypass fitting should be facing
the front of the engine. Tighten the (2) hose
clamps securing the upper hose section to the
Tstat Housing and the lower hose section to the
H.E.
Mount the Heat Exchanger assembly to the H.E.
Bracket using (2) 4” Hose Clamps (Figure 1-2,
item 55). Do not fully tighten the clamps, at this
time.

FCC
RELOCATEDT-STATASSEMBLY

RUBBERISOLATORDIPSTICKRELOCATEDHEATEXCHANGERLPFP
RELOCATED

30. From the kit, install the (2) Raw Water Dump
Hoses, using (4) 1” Hose Clamps, (Figure 1-2,
items 64-65) to the H.E. 1” outboard fittings andto the 90° fittings installed in rear ports of theexhaust manifolds.
NOTE: The starboard r/w dump hose may need to
be trimmed slightly, at the H.E. side, to prevent it fromrubbing on the corner of the starboard head.

10-PINRELOCATED

H.E. BRKT.
MOUNTING
BOLTS

Figure 1-15 FWC Assembly Locations - Rear ofEngine31. Connect the Fresh Water Supply Hose (from thecirc. pump) to the H.E. lower starboard fitting
using 1-1/2” Hose Clamp (Figure 1-2, item 3).
32. Connect the Fresh Water Fill Hose (from theDegas Bottle) to the H.E. upper starboard 3/4”
fitting using 3/4” Hose Clamp (Figure 1-2, item
30).
BYPASSHOSE

33. Connect the Fresh Water Return Hose (fromthe Water neck Outlet) to the H.E. thermostat
housing 1-1/2” fitting using 1-1/2” Hose Clamp(Figure 1-2, item 11).

F/W
RETURNF/W FILLHOSE

R/W
SUPPLY

34. Connect the Bypass Hose (from circ. pump) to
the H.E. thermostat housing 5/8” fitting using the5/8” Hose Clamp (Figure 1-2, item 17).

R/W
DUMP

35. Connect the Raw Water Supply Hose (from theraw water pump) to the H.E. 1-1/4” fitting, upper
port side of the H.E., using 1-1/4” Hose Clamp(Figure 1-2, item 13).
IMPORTANT: If your V-drive application routes theoutput of the raw water pump directly to the V-drive
gear unit; you will not use the Raw Water Supply
Hose supplied in the kit. You will need to obtainfrom the boat builder/or fabricate a hose of sufficient
length to come from the output of the V-drive gear to
the raw water input of the Heat Exchanger. The hoseshould be 1-1/4” i.d. to fit properly to the H.E.

H.E.
GROUNDF/W
SUPPLY

Figure 1-16 Hose Connections - Rear of Engine

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RK147050A

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
36. From the kit, use the Nut w/lock washer (Figure
1-2, item 67) to secure the ground wire to the
H.E. ground stud.
37. From the kit, affix decals (Figure 1-2, items
59-62, Figure 1-2 also shows approximate
location of the decals) to the Heat Exchanger.

WARNING
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline
is extremely flammable and highly explosive undercertain conditions. Be sure the ignition key is off anddo not smoke or allow open flame in the area whileservicing. Wipe up any spilled fuel immediately.
38. Disconnect the Low Pressure Fuel Pump fuelline from the FCC. Remove the (3) FCC
attaching bolts, keeping the FCC in an uprightposition, to avoid spilling any fuel, install the
FCC onto the new FCC Bracket (installed instep 26), using the FCC attaching bolts. The
FCC should orientate into the new bracket so theelectrical harness comes through the bracket atthe point nearest the engine.

LPFP BRKT.
MOUNTING
LOCATION
FUEL
RETURNTO TANK

39. From the kit, install the new HP supply to rail,
fuel line (Figure 1-2, item 46), to the FCC. From
the kit, install the new HP return from rail, fuelline (Figure 1-2, item 47), to the FCC.
NOTE: The Heat Exchanger may need to be moved
slightly to the starboard side of the engine to allow
clearance for the FCC.

FCC

LPFP TO FCCFUEL LINEFUEL
SUPPLYFROM TANKLOWPRESSURE
FUEL PUMP

40. Reconnect the fuel tank return fuel line to the
FCC. (disconnected in step 22)
41. Ensure that the H.E. r/w and f/w drains arefacing straight down. From the kit, installa rubber isolator (Figure 1-2, item 54) undereach of the H.E. mounting clamps, then tighten
clamps securing the H.E. to the H.E. Mounting
Bracket.

18

L591002
RK147050A

Figure 1-17 FCC/LPFP Mounting

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVEWARNING
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline
is extremely flammable and highly explosive undercertain conditions. Be sure the ignition key is off anddo not smoke or allow open flame in the area whileservicing. Wipe up any spilled fuel immediately.
42. From the kit, obtain the LPFP Bracket, and LPFP
output fuel fitting (Figure 1-2, items 37, 45).
Retaining all attaching hardware, remove the
LPFP from the bracket, and install the LPFP
onto the new LPFP Bracket. The output fitting of
the LPFP will face port (see Figure 1-18).
43. Loosen, do not remove, the three (3) FCC
attaching bolts. With the LPFP attached to the
LPFP Bracket, slide the bracket slots onto the
FCC attaching bolts. Tighten the bolts securely.
44. Connect the Low Pressure Fuel Pump to FCC
fuel line to the FCC input connector.
LPFP BRKT.
MOUNTING
LOCATION

45. Reconnect the fuel tank supply fuel line to the
LPFP.

FUEL
RETURNTO TANK

46. Route the fuel lines connected to the top of
the FCC under the Bypass Hose and the Raw
Water Supply Hose. Connect the HP Supply toRail fuel line (fuel line nearest to the electricalharness on the FCC) to the upper fitting on thefuel rail. Connect the HP Return from Rail fuelline to the lower fitting of the fuel rail. Secureboth fuel lines with the fuel line retaining clips
removed in step 21.
47. Reconnect the FCC harness to its engine
harness connector. Route the engine harness
connector up and over the port side R/W Dump
Hose connected to the H.E.

L591002
RK147050A

FCC

LPFP TO FCCFUEL LINEFUEL
SUPPLYFROM TANKLOWPRESSURE
FUEL PUMP

Figure 1-18 FCC/LPFP Mounting

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
DEX-COOL™ can become contaminated byinadvertently topping-off with conventional coolant,
adding conventional coolant to the system or evenif fill/drain containers are shared between coolants.
If contamination occurs, the cooling system must be
immediately drained and flushed, and refilled with DEXCOOL™. No short-term damage will occur, however, theservice interval will be reduced from 5 years to 2 years.

WARNING
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel filter. Gasoline
is extremely flammable and highly explosive undercertain conditions. Be sure the ignition key is off anddo not smoke or allow open flame in the area whileservicing. Wipe up any spilled fuel immediately.
48. Reconnect the LPFP harness to its engine
harness connector. Route the engine side of theharness under the engine oil and transmission
fluid hoses.
49. From the kit, affix FCC “Warning” decal on the
top of the FCC Bracket. (Figure 1-2, item 39)

The fresh-water cooling side of the cooling system
must be filled with a 50/50 mixture of DEX-COOL™
(or equivalent, which meets GM6277M) extended life
antifreeze and water solution.
IMPORTANT: More than 50% antifreeze solution cancontribute to an overheating condition.
52. Reconnect negative terminal of the battery.

50. Remove the engine block drain plugs and drain
any remaining water from the engine block.
Reinstall block drain plugs.

53. Remove the pressure cap from the Degas Bottle.

51. Make sure that all drain plugs are properly
installed.

54. Prepare 5 gallons of DEX-COOL™ 50/50
solution. Fill the system with antifreeze solution
until the system is filled. Degas Bottle will be fullto the top of the bottle.

FILLING FRESH-WATER COOLING SYSTEM
55. Prime the fuel system. Turn the ignition key to
the ON position for 5 seconds, turn the key OFF
for 10 seconds, and repeat 1-3 times.

A new extended life engine coolant known as DEXCOOL™ is recommended for use in your engine. It
is imperative to note the following about DEX-COOL™
engine coolant:

WARNING•IT IS PINK IN COLOR TO DISTINGUISH IT
FROM CONVENTIONAL COOLANT.

•THE SERVICE CHANGE INTERVAL ON
ENGINES BUILT WITH DEX-COOL™ IS 5YEARS.

•TO MAINTAIN FULL CORROSIONPROTECTION DURABILITY, DEX-COOL™
MUST NOT BE MIXED WITH CONVENTIONAL(CONTAINING SILICATE) ENGINE COOLANTS.

•

Make sure that there are no fuel leaks before closing
the engine hatch.

WARNING
Visually inspect unit for fuel leaks before operating
the engine. If fuel leaks are present, DO NOT operate
the engine, repair immediately.

DEX-COOL™ IS AN ETHYLENE GLYCOL
BASED PRODUCT, THEREFORE, BOIL AND
FREEZE PROTECTION ARE MEASURED IN
THE SAME FASHION AS CONVENTIONALCOOLANTS.

56. Start the engine and operate at idle speed(800-1000 RPM) to purge any air fromthe system. When the coolant level remains
constant, install the pressure cap on the Degas
Bottle.

TO FULLY REALIZE ITS MANY ADVANTAGES,
DEX-COOL™ MUST NEVER BE MIXED WITHCONVENTIONAL COOLANTS.

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L591002
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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
57. Continue to run the engine until it reaches
normal operating temperature. Check for fuelleaks, oil leaks, fresh water coolant leaks, andraw water leaks at all fittings and connections.
Correct all leaks, as required.

WARNING
Do not remove cooling system filler cap whenthe engine is hot. Allow the engine to cool andthen remove the pressure cap slowly, allowing thepressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns.
NOTICE: It is not necessary to remove pressure cap
to check coolant levels. Check Degas Bottle daily andkeep filled to the ‘MAX” level indicated on the bottle.
58. Continue to run the engine at normal operating
temperature. Check the Degas Bottle for theproper level and add coolant if necessary.
59. From the kit, install the Hose Clamp Covers,(Figure 1-2, item 35), on all hose clamp ends.
60. From the kit, affix decals to the new hood (Figure
1-2, items 31-34) and attach the hood to theengine with the retention nuts removed in step
2.

WARNING
Make sure that there are no fuel leaks before closing
the engine hatch.
Installation of the Fresh Water Cooling Kit on a V-Drive
application is complete.

L591002
RK147050A

21

Figure 2-1 Fresh-Water Cooling System (5.7L)

22

L591002
RK147050A= Drain Locations= RAW WATER FLOW

= FRESH WATER FLOWFIGURE 2-1, FWC WATER FLOW DIAGRAM