2002 - 2003
Fresh Water
Cooling Installation
Instructions V-Drive
Kit RK147046A

L591004

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Intentially
Left Blank

L591004

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 ................................................................... 3-4
Figure 1-2, Parts Added, Raw Water System, V-Drive ................................................................... 5-7
FWC Kit Installation, V-Drive Systems ......................................................................................... 8-17
2 - Fresh Water Cooling Water Flow Diagram ................................................................................. 18

L591004
RK147046A

1

FWC KIT INSTALLATION INSTRUCTIONS - RK147046A
INSTALLATION NOTES AND
RECOMMENDATIONS

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 thehigh pressure supply 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.

PCM Technical Support, Warranty and Dealer
Assistance:•••

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

REFERENCES:
The following manuals are required to effectively perform
this installation procedure. If you do not have a copy ofeach of these manuals, obtain copies prior to beginning
this installation procedure.
L510013

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

L510010-03

Owner’s Operation and Maintenance
ManualAdditionally, to relocate the new LPFP bracket, anengine mount will need to be removed and reinstalled.
Make sure that the proper equipment required to hoist
the engine is available and in good working order.
Observe all associated safety cautions when operating
lifting equipment.

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

V-DRIVE INSTALLATIONIMPORTANT: Thoroughly read these instructions
before beginning this installation procedure. Due
to model variations between ‘02 and ‘03 modelyears, continuing product improvements, and O.E.M.
considerations, variations exist. If the motor you areinstalling the kit on is already equipped with a crank
mounted raw water pump, you will skip steps 11
through 18 and step 42 of this procedure. Kit items
17-33, 55-56 will not be used. Other variations are
addressed within the text of this procedure.
Installation of the fresh water cooling system, on someV-drive applications, will require the relocation of thetransmission oil cooler and transmission oil cooler lines.
Provisions should be made to recover oil spilled fromthe lines.

2

Fire 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.

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

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

L591004
RK147046A

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

DESCRIPTIONQUANTITY*1

R045135A

Hose, r/w pump to tstat housing

1*2

RS3858Clamp, 1 1/4”

2

3

R090082

Clamp, strap

1

4RS1527Nut, strap clamp attaching

1

5

R025031

Housing, tstat, lower

1

6

RM0121

Gasket, tstat housing, lower

1

7

R026002

Thermostat, 160º F

1

8

RM0258Gasket, tstat housing, upper

1

9R025033

Housing, tstat, upper

1

1098333080

Bolt, tstat housing

2

11

RS2179Lock Washer, tstat housing

2

1298223035

Bolt, tstat housing

11393920000

Lock Washer, tstat housing

1

14

R020002

Sender, water temperature

1

15

TBD

Plug, intake, (water temp sender)

1

16

R045048

Hose, r/w supply to engine

1

17RS3852

Clamp, 1 3/4”

2

18R045107

Hose, r/w dump

2

19RS3851

Clamp, 1”

4*20R045021F

Hose, trans. oil cooler to r/w pump

1

*21

RS5858Clamp, 1 1/4”

2

*22

R090082

Clamp, strap

1

23

R060060

Hood

1

24

R143141

Decal, hood, “PCM Excalibur”

1

25

R143142

Decal, hood, “Excalibur”

2

26

R143143

Decal, hood, spec

1

*27

R143158

Decal, hood, “3 Star” emission

1‘03 MY, ONLY, SN 430913 and higher
28

R090204

Bracket, FCC/LPFP

1

29

R143114

Decal, “WARNING” FCC/LPFP Brkt

1

30

RA085071

Fuel Line, LPFP to FCC

1

31

RA085090B

Fuel Line, HP supply to rail

1

32

RA085091B

Fuel Line, HP return from rail

1

L591004
RK147046A

3

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

DESCRIPTIONQUANTITY*33

RS0279Bolt, 10-Pin Bracket attaching

1*34

RS2179Lock Washer, 10-Pin Bracket attaching

1

35

R096144A

Bracket, plug wire clip

1

36

R096144

Bracket, plug wire clip

1

37

RA121062C

Harness, fuel pump jumper (V-drive)

1*38

R065046

Pulley, raw water pump drive belt

1

*39

R065048

Pulley, alternator drive belt

1*40

90315100

Bolt, pulleys to crankshaft balancer

3*41

RS2180

Lock Washer, pulleys to crankshaft balancer

3*42

R066026

Belt, raw water pump drive

1*43RA057031

Raw Water Pump Assembly

1*44

R065047

Pulley, raw water pump

1

*45

RS0775Bolt, raw water pump pulley attaching

3*46

RS2179Lock Washer, r/w pump pulley attaching

3*47

RS0282

Bolt, raw water pump mounting

2*48

RS2179Lock Washer, raw water pump mounting

2*49

R090264

Bracket, raw water pump adjust

1*50

RS0327

Bolt, adjustment brkt to mount2*51

RS2181

Lock Washer, adjustment brkt to mount2*52

R090263

Bracket, raw water pump mount1*53

RS0307

Bolt, mount to block2*54

RS2181

Lock Washer, mount to block2*55

RA045007B

Hose, transmission oil

1*56

RA045007K

Hose, transmission oil

1*57

RS0306

Bolt, trans. cooler attaching

1*58

RS2180

Lock Washer, trans. cooler attaching

1*59

RS1028Nut, trans. cooler attaching

1

IMPORTANT: ITEM NUMBERS MARKED WITH AN “*” MAY OR MAY NOT BE DELETED
DEPENDING ON YOUR ENGINE CONFIGURATION. BE SURE TO READ ALL INSTRUCTIONSTHOROUGHLY BEFORE PERFORMING THE FWC KIT INSTALLATION INSTRUCTIONS.
REFER TO MANUAL L510013 FOR PARTS BREAKOUT.

4

L591004
RK147046A

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

DESCRIPTION

1

R020003

Sender, water temperature

1

2

R090260

Bracket, coolant fill riser

1

398223016

Bolt, fill riser brkt attaching

2

4

RS2672

Lock Washer, fill riser brkt, attaching

2

5RS7068Flat Washer, fill riser brkt, attaching

2

6

R034047

Coolant Fill Riser

1

7

R034006A

Cap, coolant fill riser

1

8RS0252

Bolt, fill riser mounting

2

9RS2179Lock Washer, fill riser mounting

2

10

RS1026

Nut, fill riser mounting

2

11

R025015A

Housing, FWC thermostat

1

12

R026002F

Thermostat, 160° F

1

13

R047189

O-Ring, thermostat housing

1

14RS6531

Bolt, thermostat housing attaching

2

15

RS2179Lock Washer, thermostat housing attaching

2

16

R024055

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

1

*17

R065045

Pulley, crankshaft

1*18

RA057026

Raw Water Pump Assembly, crank driven

1*19R009161

Bolt, r/w pump mounting

3*20

RS2180

Lock Washer, r/w pump mounting

3*21

R090177A

Bracket, raw water pump mounting

1*22

R094038

Grommet, rubber

1*23

RS0302

Bolt, r/w pump brkt mounting

2*24

RS2180

Lock Washer, r/w pump brkt mounting

2*25

RS0280Bolt, r/w pump to brkt attaching

1*26

RS2179Lock Washer, r/w pump to brkt attaching

1*27

RS2673

Flat Washer, r/w pump to brkt attaching

1*28

R090013A

Bracket, trans. oil cooler mounting

1*29

RS0302

Bolt, cooler clamp to brkt attaching

1*30

RS2180

Lock Washer, cooler clamp to brkt attaching

1*31

RS1028Nut, cooler clamp to brkt attaching1

L591004
RK147046A

QUANTITY

5PARTS ADDED - 5.7L, V-BELT, V-DRIVE -F/W
FIGURE 1-2

6

ITEM

PART NUMBER

DESCRIPTION*32

RA045007S

Hose, transmission oil to cooler, 17”1*33

RA045007T

Hose, transmission oil to cooler, 31”

1

34

R090188

Bracket, FCC

1

35

R143114

Decal, “WARNING”

1

36

R090223

Bracket, LPFP

1

37

RA085090A

Fuel Line, HP supply, FCC to rail

1

38

RA085091A

Fuel Line, HP return, rail to FCC

1*39

R090265

Bracket, heat exchanger

1*40

RS0281

Bolt, (-265) brkt, heat exchanger attaching

2*41

RS2179Lock Washer, (-265) brkt, heat exchanger

2*42

R090266

Bracket, heat exchanger

1*43

RS0304

Bolt, (-266) brkt, heat exchanger attaching

2*44

RS2180

Lock Washer, (-266) brkt, heat exchanger

2

45

RS0302

Bolt, engine harness ground to head

1

46

RS2180

Lock Washer, harness ground to head

1

47

R101013

Wire, H.E. ground1

48

R094040

Isolator, rubber, adhesive

149

RA147046

Heat Exchanger

1

50

R094041

Isolator, rubber

2

51

RS3857

Clamp, 4”2

52

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

53

R045025

Hose, r/w dump, 1”

2

54RS3851

Clamp, 1”

4*55

R045113

Hose, trans. oil cooler to r/w pump

1

*56

RS3858Clamp, 1 1/4”

2

57

R045146

Hose, circ. pump to H.E.

1

58

RS3852

Clamp, 1 3/4”, circ. pump

1

59

RS3868Clamp, 1 1/2”, H.E.

1

60

R045102A

Hose, r/w pump to H.E.

1

61

RS3858Clamp, 1 1/4”

2

L591004
RK147046A

QUANTITY

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

DESCRIPTIONQUANTITY

62

R045124

Hose, coolant fill riser to H.E.

1

63

RS3851

Clamp, 1”

2

64

R045144

Hose, t-stat housing to H.E.

1

65

RS3858Clamp, 1 1/4”

2

66

R045132

Hose, coolant fill riser to t-stat housing

167

RS3870Clamp, 1/4”

2

68

R045139

Hose, overflow bottle to coolant fill riser

1

69

R127084

Clamp, 1/4”

2

70

R146002

Coolant Overflow Bottle w/cap

1

71RS0282

Bolt, overflow bottle mounting

2

72

RS2673

Flat Washer, overflow bottle mounting

2

73

RS2179Lock Washer, overflow bottle mounting

2

74

RS1027Nut, overflow bottle mounting

2

75

R060061A

Hood

1

76

R143141

Decal, hood, “PCM Excalibur”

1

77

R143142

Decal, hood, “Excalibur”

2

78

R143143

Decal, hood, spec

1

*79

R143158

Decal, hood, “3 Star” emission

1‘03 MY, ONLY, SN 430913 and higher

IMPORTANT: ITEM NUMBERS MARKED WITH AN “*” MAY OR MAY NOT BE USEDDEPENDING ON YOUR ENGINE CONFIGURATION. BE SURE TO READ ALL INSTRUCTIONSTHOROUGHLY BEFORE PERFORMING THE FWC KIT INSTALLATION INSTRUCTIONS.
REFER TO MANUAL L510013 FOR PARTS BREAKOUT.

L591004
RK147046A

7

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVEFWC KIT INSTALLATION - V-DRIVEINTAKE
MANIFOLD
PLUG

1. Disconnect the negative battery terminal cable.
2. Remove the hood (Figure 1-1, item 23) 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.

T-STAT
HOUSING
BOLTS

3. Remove the thermostat housing, watertemperature sender, and associated hoses.

Figure 1-3 Disconnect Points - Steps 3 - 4.
NOTE: The complete thermostat housing with hoses,
temp sender, and thermostat can be remove as an
assembly. (Figure1-1, items 1-22)
a. Disconnect the wire connected to
the water temperature sender (Figure
1-1, item 14), located in the lower
thermostat housing.

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.

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, theraw water pump hose retaining clamp
and retaining nut on the lower port studof the circulating pump, and the raw
water supply to engine hose at thecirculating pump.
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
the thermostat and remove the hose retaining clamp
and nut at the lower port circulating pump mounting
stud, then continue with this procedure.
c. Remove the two bolts and lockwashers (Figure 1-3) 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.
4. Remove and discard the plug located right, frontof the intake manifold. Figure 1-3.

8

L591004
RK147046A

5. From the kit, install the Water Temperature
Sender (Figure 1-2, item 1) into the intake
manifold, where the plug was removed, andreconnect the temperature sending wire to thesensor. This is the wire disconnected in step 3a.
6. 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. Be sure to clean the threads ofeach fitting, then apply PST prior to installation.

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.
7. From the kit, install the Coolant Fill Riser Bracket
using (2) Bolts (*metric), (2) Lock washers, and(2) Flat washers (Figure 1-2, items 2 - 5). The
bracket is installed to the existing bracket on the(engine) starboard side of the intake manifold.
8. From the kit, install the Coolant Fill Riser onto the
Coolant Fill Riser Bracket using (2) bolts, (2) lockwashers, and (2) nuts (Figure 1-2, items 6-10).
The fill riser is mounted on the exhaust elbow
side of the bracket. Install pressure cap onto fillriser.
9. From the kit, install the Thermostat, O-ring, andThermostat Housing using (2) Bolts, (2) Lockwashers, (Figure 1-2, items 11 - 15).
10. From the kit, install the Vent Hose Fitting(Figure 1-2, item 16) into the Thermostat
Housing. The hose barb should be positioned
to starboard, approximately parallel with the
Thermostat Housing outlet.
* IMPORTANT: STEPS 11 - 18 ARE ONLYPERFORMED IF YOUR ENGINE IS EQUIPPED WITH
A V-BELT DRIVEN RAW WATER PUMP.
11. Remove the v-belt driven raw water pump andall associated brackets. This can be done as
an assembly including pump, bracket, mount,pulley, and belt. Disconnect water hosesconnected to the input and output of the pump.
Remove the (2) bolts and (2) lock washers
securing the r/w pump mount to the block. The
pump, drive belt and all associated components
will not be required to complete this procedure.
12. Remove the crankshaft pulleys. Loosen
the alternator adjusting strap bolt to relievetension on the alternator v-belt. Remove the(3) bolts and (3) lock washers securing thepulleys to the crankshaft balancer. Remove
the crankshaft balancer retaining bolt and flat
washer. Remove both pulleys and discard thepulleys. Retain the crankshaft balancer bolt
and flat washer, and at least (2) of the pulleyretaining bolts.

L591004
RK147046A

FILL
RISER
MOUNT

Figure 1-4 Coolant Fill Riser Bracket Location
13. From the kit, install the new Alternator Drive
Belt Pulley (Figure 1-2, item 17). Locate thepulley onto the crankshaft balancer, using (2)of the pulley bolts removed in step 12, install
the bolts through two of the screw holes andhand tighten to properly locate the pulley. Install
the crankshaft balancer retaining bolt and flat
washer, then torque to 70 lb.ft. Remove the(2) bolts used to properly locate the pulley.
14. Reinstall the alternator v-drive belt on the
crankshaft pulley and alternator pulley. Do not
set tension on the v-belt at this time.
15. From the kit, install the Crank Driven Raw Water
Pump using (3) bolts and (3) lock washers to the
crankshaft balancer (Figure 1-2, items 18-20).
Once the pump is installed, by hand, rotate
the pump until the pump’s mounting boss is
positioned toward the bottom of the boat.
16. From the kit, locate the Raw Water Pump
Mounting Bracket, Rubber Grommet, Raw
Water Pump to Brkt. mounting (1) bolt, (1) flat
washer, (1) lock washer, and Bracket Mounting(2) bolts, and (2) lock washers (Figure 1-2,
items 21 - 27). Install the rubber grommet into
the large hole of the bracket. Locate the r/w
pump mounting boss into the rubber grommet,then locate the bracket mounting holes with theblock mounting holes (holes vacated when old
r/w mount was removed), secure the bracket tothe block using (2) bolts and (2) lock washers(Figure 1-2, items 23 - 24). Ensure that ther/w pump mounting boss does not come outof the rubber grommet when tightening bracket
mounting bolts.

9

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
16. (continued) Secure the r/w pump to the bracket
using (1) bolt, (1) lock washer, and (1) flat
washer through the bottom of the bracket,
through the rubber grommet into the r/w pump
mounting boss.

c. Remove the oil cooler, with mounting clamp
attached, from the engine. The cooler clamp
will be secured to the engine either by aground stud bolt on the bell housing or a bolt,
lock washer, and nut through a mounting holeon the bell housing. If it was secured by theground stud, replace the ground stud and all
grounds after removal of the cooler; if it was
secured by a bolt, lock washer, and nut, those
items may be discarded.

17. Set the proper tension on the alternator belt.
1/2” deflection at mid-point of belt, and secure
alternator strap adjusting bolt.
NOTE: The following procedure involves the relocationof the Transmission Oil Cooler and oil hoses. Havematerials in place to absorb any transmission fluid
spilled.

d. The transmission oil line fittings need to be
re-indexed. Remove the top fitting on thetransmission, clean the threads, coat threads
with PST, and reinstall the fitting so it is facing
the front of the engine at an approximate 45°
angle to port. Remove the lower port oil line
fitting on the transmission, clean the threads,
coat the threads with PST, and reinstall thefitting so it is facing down with a slight angle
toward the engine.

IMPORTANT: In most cases, engines equipped withthe v-belt driven r/w pump will have the oil cooler
located on the starboard rear of the engine. If yourengine has the oil cooler located on the starboard
rear of the engine, you must perform step 18.
18. Relocate the Transmission Oil Cooler fromits rear, starboard location to engine port front
motor mount.

NOTE: To minimize transmission fluid spillage in theboat, once the cooler has been removed from its
mounting point, perform step e on a work bench.

a. Disconnect water hoses connected to the
input and output of the cooler. The water
hose connected to the output of the cooler
should be removed completely from theengine. You will have to release the hose
clamp securing the hose to the starboard
side of the engine by removing the bolt andlock washer securing it at the starboard front
engine mount; after the clamp is removed
reinstall the bolt and lock washer into themotor mount.
NOTE: It is recommended that the transmission fluid
be removed from the transmission at this time. This
will help minimize the amount of fluid spilled during thecooler relocation process.

e. The transmission oil line fittings will need to be
re-indexed. Remove the oil line fittings fromthe oil cooler. Clean the threads thoroughly,
apply PST to the fitting threads, and reinstall
the fittings into the oil cooler so the rear fitting
is parallel with the cooler facing the rear of
the engine, and the forward fitting is facing therear at a slight up angle to allow for oil hose
attachment. See Figure 1-5.
LARGE HOLE
MOUNTS TO
TRUNNION
BOLTTOWARD
ENGINEFRONTCOOLER
BRACKETb. Disconnect and remove the transmission oil
hoses from the oil cooler and the transmission
and discard hoses. Have materials available
to absorb transmission fluid that will spill fromthe lines, cooler, and transmission.

TO
TOP
TRANSMISSIONFITTING

COOLER
CLAMP
ORIENTATECOOLER SO
DRAIN FITTING
IS DOWNTO
BOTTOM
TRANSMISSIONFITTING

Figure 1-5 Transmission Oil Cooler, Reconfigured

10

L591004
RK147046A

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
f. From the kit, locate the Oil Cooler Bracket,(1) bolt, (1) lock washer, (1) nut, and (2)Transmission Oil Hoses (Figure 1-2, items 28- 33). If necessary, loosen the cooler clamp
and orientate the cooler to the position shownin Figure 1-5. Tighten the clamp. Attach thecooler bracket to the cooler clamp as shownin Figure 1-5. Attach the shorter of the twotransmission oil line hose to the rear oil fittingof the cooler. Attach the longer transmission
oil line hose to the forward fitting on the oilcooler.
LARGE HOLE
MOUNTS TO
TRUNNION
BOLTTOWARD
ENGINEFRONTCOOLER
BRACKETTO
TOP
TRANSMISSIONFITTING

COOLER
CLAMP
ORIENTATECOOLER SO
DRAIN FITTING
IS DOWNWARNING
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.
IMPORTANT: Installation of the fresh watercooling system on V-drive applications will require
relocation of both the low pressure fuel pump andthe FCC, and servicing of the high pressure
supply and return fuel lines. To complete theinstallation procedure you will require a fuel gauge
equipped with a pressure release valve, an approved
container to vent gasoline into, and the proper
tools for releasing the fuel lines from the fuel rails.
Provisions should be made to recover any fuelspilled. Observe all safety warnings and cautions
when working on the fuel system.
Additionally, to relocate the new LPFP bracket,
an engine mount will need to be removed andreinstalled. Make sure that the proper equipment
required to hoist the engine is available and ingood working order. Observe all associated safety
cautions when operating lifting equipment.

TO
BOTTOM
TRANSMISSIONFITTING

Figure 1-5 Transmission Oil Cooler, Reconfigured
g. Mount the assembled cooler to the engine port
front motor mount trunnion bolt. Remove thenut and lock washer from the trunnion bolt,
slide the oil cooler bracket onto the trunnion
bolt and secure with the nut and lock washer.
Once installed the cooler may need to
be rotated up or down slightly for best fit.
Make sure all mounting hardware is secure ifloosened for fit adjustment.
h. Route the transmission oil line hoses under
the remote oil filter lines. Attach the shortertransmission oil line hose to the bottom fitting
on the transmission, and the longer hose to
the upper fitting on the transmission. Make
sure all oil line hose connections are secure.
IMPORTANT: CHECK TRANSMISSION FLUIDLEVEL. IF IT IS NOT TO THE “FULL” MARK OF THE
DIPSTICK, ADD FLUID AT THIS TIME UNTIL FLUIDLEVEL INDICATES FULL.

L591004
RK147046A

19. Disconnect electrical connections to the FCC
and LPFP fuel pumps.
20. 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 (IF EQUIPPED) fromboth the high pressure supply and return fuellines, at the fuel rail. Using the appropriate tool,
release both lines from the fuel rail. Fuel lines
will contain 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 1-6.
21. Disconnect the fuel tank return line from the
FCC. Keep line elevated and use appropriate
measures to minimize fuel leakage.
22. Disconnect the fuel tank supply line from the
LPFP. Keep line elevated and use appropriate
measures to minimize fuel leakage.

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
26. 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 in step 25),
using the FCC attaching bolts. The FCC shouldorientate into the new bracket so the electricalharness comes through the bracket at the pointnearest the engine’s circulating pump pulley.

FUEL
LINE
RETAINERHP
SUPPLY
FUEL LINE

HP
RETURNFUEL LINEA

SCHRADER
VALVE

Figure 1-6 Fuel Rail Service Points
24. Remove (3) bolts and (3) lock washers securing
the FCC/LPFP bracket to the rear of the engine’s
port head. Remove bracket with FCC and LPFP
attached and set aside.
NOTE: The bracket and spark plug wire clip bracket will
not be reused. The FCC bracket attaching hardware,
FCC, FCC attaching hardware, and fuel fittings will bereused in later steps, as will the LPFP with its associatedhardware.
IMPORTANT: The FCC and LPFP will contain fuel,make sure they are temporarily stored in an uprightposition so fuel will not spill from them.
25. From the kit, locate the new FCC Bracket(Figure 1-2, item 34), install the bracket using
the (3) bolts and (3) lock washers, retained fromstep 24, to the front of the engine’s starboard
head. From the kit, affix “WARNING” decal(Figure 1-2, item 35) on the top surface of the
FCC Bracket.

27. From the kit, install the new HP supply to rail,
fuel line (Figure 1-2, item 37), to the FCC. From
the kit, install the new HP return from rail,
fuel line (Figure 1-2, item 38), to the FCC.
Fuel lines will route to the rear of the engine
along the starboard side of the intake manifold
and bend around to the port side fuel rail
connections. Follow the steps below to ensure
good connections at the fuel rail.
a. Push the fuel lines, near the connection point(A), onto the fuel rail.
b. Pull on the fuel lines near the connection point(A) with an approximate force of 10 lb.ft. (44N). There will be some movement due to thedesign of the connection. If the fuel lines do
not become separated from the fuel rail whenforce is applied, the fuel lines are connected
and sealed properly.
c. If either of the fuel lines become separated
from the fuel rail, reassemble by pushing thefuel line(s) back on to the fuel rail until a“click” is heard. After reassembling the fuelline(s), repeat step (b) to verify the proper
connection.
d. If your engine was equipped with fuel line
retaining clips, reinstall the clips on both fuellines.
28. Position an engine hoist over the engine. Make
connections between the engine lift rings andthe hoist. Slowly adjust tension on the hoist until
a firm tension is achieved on the lift apparatus.
You do not need to elevate the engine, justrelieve pressure on the engine mount.

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.

a. Loosen the nut on the engine’s front starboard
trunnion bolt. Lightly tap the bolt to release it
from the trunnion.
b. Remove the (3) bolts and (3) lock washers
securing the engine mount to the block.

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
28. c. Slide the motor mount along the trunnion
away from the block. Position the LPFP
Bracket (Figure 1-2, item 36) between themount and the block. Slide the mount backto the block and secure the mount and
LPFP bracket with the (3) bolts and (3) lockwashers removed in step (b).
d. Relieve tension on hoist and remove lifting
apparatus.
29. On the old FCC/LPFP Bracket, retaining all
attaching hardware, remove the LPFP from thebracket, and install the LPFP onto the new
LPFP Bracket. The output fitting of the LPFP
will face forward (engine front). See Figure 1-7.

Figure 1-7 LPFP Bracket and LPFP Relocated

30. Reconnect the output of the LPFP to the inputof the FCC.

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.

WARNING
With the relocation of the FCC/LPFP new fuellines may need to be run from the fuel tank to
the FCC return and LPFP input. Use marine
approved 3/8” fuel line. DO NOT splice extra
length onto the existing lines in order to makeconnection to the FCC/LPFP.
31. Connect return-to-tank fuel line to FCC.
32. Connect fuel tank supply line to LPFP input.
33. Remove the Fuel Pump Jumper Harness fromthe main engine harness. Connect FCC and
LPFP to the main engine harness.
NOTE: LPFP harness connection may be tied off to themain engine harness. Cut tie wrap and route forwardand down to make connection to the LPFP.
34. Remove the starboard plug wire retaining
bracket, located on the rear of the starboard
head. Reinstall bolt and lock washer securing
dipstick tube bracket.

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
NOTE: For steps 35 -37 of this procedure parts added
and relocated will vary according to the Bell Housing
installed on your engine. Refer to Figure 1-8 for Bell
Housing differences. Figure 1-8A is distinguished byhaving ‘PCM’ cast into the upper center surface and isa bottom mount starter only housing. Figure 1-8B is thecurrent style Bell Housing and is distinguished by being
able to accept either top mount or bottom mount starters
dependent upon application.
35. Relocate the 10-Pin Bracket to the lower top
mount starter block-off plate bolt, or to the upper
starboard transmission mounting bolt. Refer toFigure 1-8. If a ground wire was secured at
the 10-Pin Bracket mounting point, relocate thisground wire to the lower mounting hole on therear of the starboard head using (1) bolt and(1) lock washer, from the kit (Figure 1-2, items
45-46). If the 10-Pin bracket was originallysecured with a ground stud bolt (typical of
Figure 1-8B) return the bolt to its original
location and tighten. If the 10-Pin was secured
by a bolt and lock washer (typical of Figure
1-8A) you may discard the bolt and lock washer.

HEAT EXCHANGERBRACKETLOCATIONHEAT EXCHANGERGROUND WIRELOCATION

10-PIN BRACKETNEW LOCATIONAHEAT EXCHANGERGROUND WIRELOCATION

10-PIN BRACKETNEW LOCATION

B

38. From the kit, cut the rubber isolator withadhesive into thirds (Figure 1-2, item 48). Affix
the isolator onto the Heat Exchanger Bracket in
the center and inboard of each of the mounting
clamp holes.
NOTE: The Remote Oil Lines will route behind (engineside) the H.E. Bracket.
39. From the kit, obtain the Heat Exchanger (Figure
1-2, item 49). Mount the Heat Exchanger
assembly to the H.E. Bracket using (2) 4” Hose
Clamps (Figure 1-2, item 51). Do not fullytighten the clamps, at this time.
40. From the kit, use the Nut w/lock washer (Figure
1-2, item 52) to secure the ground wire to the
H.E. ground stud.

14

10-PIN BRACKET
OLD LOCATIONHEAT EXCHANGERBRACKETLOCATION

36. From the kit, install the Heat Exchanger Ground
Wire (Figure 1-2, item 47) at the upper port bell
housing mounting bolt. Refer to Figure 1-8 forexact location.
37. From the kit, install the Heat Exchanger Bracket(Figure 1-2, items 39 - 44) to the bell housing.
For the bell housing pictured in Figure 1-8A use
items 39-41 from the kit, for the bell housing
pictured in Figure 1-8B use items 42-44 fromthe kit.

10-PIN BRACKET
OLD LOCATION

L591004
RK147046A

Figure 1-8 Bell Housing Configurations andAccessory Mounting Locations

FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
41. From the kit, install the (2) Raw Water Dump
Hoses, using (4) 1” Hose Clamps, (Figure 1-2,
items 53-54) to the H.E. 1” outboard fittings andto the 90° fittings installed in rear ports of theexhaust manifolds.

47. From the kit, install the Coolant Fill Riser tothermostat Housing Hose (Figure 1-2, item 66),
using 1/4” hose clamps (Figure 1-2, item 67).
This hose connects to the nipple fitting locatedon the engine front of the fill riser and routes
inside the oil fill tube to the thermostat housing
fitting.

NOTE: The r/w dump hoses may need to be trimmed
slightly, at the H.E. side, to prevent them from rubbing on
the corner of the engine heads.

48. From the kit, locate the Coolant Overflow
Bottle w/Cap, Coolant Overflow Hose, 1/4”
Hose Clamps, and Overflow Bottle mounting
hardware, (2) bolts, (2) flat washers, (2) lockwashers, and (2) nuts (Figure 1-2, items 68-74).
Attach the coolant overflow hose to the overflow
bottle using 1/4” hose clamp. Mount theOverflow Bottle to the Heat Exchanger Bracket
using the (2) bolts, flat washers, lock washers
and nuts. Bolt with flat washer on the bottle side
and lock washer and nut on bracket side. Routethe overflow hose under the H.E. then up andforward to the engine rear fitting on the coolant
fill riser and secure with 1/4” hose clamp.

42. If you performed steps 11-18 of this procedure,from the kit, install the Cooler to R/W Pump
Hose (Figure 1-2, item 55) using hose clamps
provided (Figure 1-2, item 56). The hose mayneed to be trimmed at the cooler side to provide
a smooth fit. Hose will attach to the lower fittingof the crank driven r/w pump.
43. From the kit, install the Circulating Pump to
Heat Exchanger Hose (Figure 1-2, item 57).
Use 1-3/4” hose clamp (Figure 1-2, item 58) at
the circulating pump and use 1-1/2” hose clamp(Figure 1-2, item 59) at the H.E. The hose mayneed to be trimmed at the heat exchanger end
to provide a smooth fit.

49. Ensure that the H.E. r/w and f/w drains arefacing straight down. From the kit, installa rubber isolator (Figure 1-2, item 50) undereach of the H.E. mounting clamps, then tighten
clamps securing the H.E. to the H.E. Mounting
Bracket.

44. From the kit, install the R/W Pump to Heat
Exchanger Hose (Figure 1-2, item 60) using
1-1/4” hose clamps (Figure 1-2, item 61).
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. Connect the output of the
Crank Driven Raw Water Pump to a hose going tothe V-drive gear unit and the cooling hose comingfrom the V-drive gear unit to the rear fitting (r/w
input) of the heat exchanger, as your application
requires. Hoses disconnected as part of thisprocedure may be of sufficient length to accomplish
this or you may need to order 1-1/4” i.d. water hoseof sufficient length from the O.E.M. or other source.

IMPORTANT: If you performed step 18 of thisprocedure, relocation of the transmission oil cooler
will require a new water intake hose between thecooler and the seacock (or sea strainer, depending
upon application). Hoses disconnected during thisprocedure may be of sufficient length to accomplish
this or you may need to order 1-1/4” i.d. water hoseof sufficient length from the O.E.M. or other source.
Ensure that this connection is made before you
operate the engine.

45. From the kit, install the Coolant Fill Riser toHeat Exchanger Hose (Figure 1-2, item 62),
using 1” hose clamps (Figure 1-2, item 63). The
moulded end of the hose will connect to thefill riser and the end of the hose connecting to
the H.E. may need to be trimmed to provide asmooth fit.

50. Remove the engine block drain plugs and drain
any remaining water from the engine block.
Reinstall block drain plugs.
51. Make sure that ALL drain plugs are properly
installed and all hose connections (fuel, oil, andwater) are secure.

46. From the kit, install the Thermostat Housing
to Heat Exchanger Hose (Figure 1-2, item 64),
using 1-1/4” hose clamps (Figure 1-2, item 65).

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVE
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.

FILLING FRESH-WATER COOLING SYSTEM
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:•

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.

•

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

WARNING
Visually inspect unit for fuel leaks before operating
the engine. If fuel leaks are present, DO NOT operate
the engine, repair immediately.
56. Start the engine and operate at idle speed(650-1000 RPM) to purge air from the system.
Continue to add coolant until the coolant levelremains constant, install the pressure cap on
the Coolant Fill Riser. Then add coolant to theOverflow Bottle to the “Full” mark on the bottle.

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

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

WARNING

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.
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.

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

IMPORTANT: More than 50% antifreeze solution cancontribute to an overheating condition.
52. Reconnect negative terminal of the battery.
53. Remove the pressure cap from the Coolant Fill
Riser.
54. Prepare 5 gallons of DEX-COOL™ 50/50
solution. Slowly fill the system with antifreeze
solution until the system is full. Coolant Fill Riser
will be full to the top.

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FWC KIT INSTALLATION INSTRUCTIONS - V-DRIVEWARNING
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 Overflow Bottle daily
and keep filled to between the ‘ADD” and “FULL” levelindicated on the bottle.
58. Continue to run the engine at normal operating
temperature. Verify engine operating
temperature and thermostat operation. Check
the Overflow Bottle for the proper level and add
coolant if necessary.
59. Tun engine off. Check transmission fluid level.
If the level is not to the ‘FULL’ mark on thedipstick add fluid to bring it to the proper level.
60. From the kit, affix decals to the new hood (Figure
1-2, items 75-79) 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.

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17

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

18

L591004
RK147046A= Drain Locations= FRESH WATER FLOW

= RAW WATER FLOWTo Cylinder
Block

To Cylinder
Block

From Intake
Manifold

FIGURE 2-1, FWC WATER FLOW DIAGRAM