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Crusader Challenger 5.7L Catanium CES - User Manual

Crusader Challenger 5.7L Catanium CES
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OWNER’S OPERATION
and
MAINTENANCE MANUAL

Table of Contents

Questions and Answers

Crusader Challenger 5.7L Catanium CES Specifications

General IconGeneral
BrandCrusader
ModelChallenger 5.7L Catanium CES
CategoryEngine
LanguageEnglish

Summary

Manual Introduction and Guidance

Read This Manual Thoroughly

Emphasizes careful and complete reading of the manual for understanding procedures and seeking clarification.

Safety and Regulatory Information

Proposition 65 Warning

Informs about chemicals in engine exhaust known to cause cancer, birth defects, or reproductive harm in California.

Introduction and Registration

Registration Information

Details the process of registering the engine and encourages feedback via customer survey.

Warranty Information

3 Year Transferable Limited Warranty

Outlines terms, coverage, exclusions, and procedures for the transferable limited warranty.

Federal;California Emission Control Warranty

Explains emission control system warranty coverage and owner responsibilities for compliance with regulations.

General Emissions Warranty Coverage

Details the warranty period and coverage for emission control devices on engines manufactured after specific dates.

Emissions Warranty Covered Parts

Lists specific engine components covered under the emissions warranty, including fuel, air, ignition, and exhaust systems.

Safety and Precautions

Safety Warnings and Symbols

Explains safety symbols (Danger, Warning, Caution, Important) and emphasizes compliance for accident prevention.

Replacement Parts Guidance

Advises using genuine Crusader Challenger replacement parts to avoid fire or explosion hazards.

Boating Responsibilities and Hazards

Carbon Monoxide Hazard

Warns about the dangers of Carbon Monoxide (CO) and how to prevent exposure in boat environments.

Safe Boating Suggestions

Recommends safety courses and lists organizations for boating safety education.

Water Wisdom for Safe Operation

Provides suggestions for safe boat operation, including loading, checks, responsible behavior, and weather awareness.

Owner Operation and Maintenance Responsibility

States the owner/operator's responsibility for safety checks and adherence to maintenance schedules.

Navigational Rules and Safe Practices

Channel Buoy Guide

Explains the meaning of channel buoys (Nun, Can, Lighted) for navigation and channel identification.

Engine and Owner Identification

Engine Identification

Guides on locating the engine model and serial number for service and information requests.

Owner Identification and Registration

Advises recording owner and boat details for quick reference when ordering parts or requesting service.

Engine Model Identification

Details the structure of the engine model number, explaining codes for manufacturing, engine type, drive, and specification.

Electronic Fuel Injection System

EFI System Overview

Explains the EFI system, its components (pumps, throttle body, injectors), and the ECM's role in controlling fuel and spark.

Operating Instructions

Engine Alarm System

Describes the engine alarm system, including indicator lamps (MIL, CGL) and buzzer functions for warnings.

Instrumentation Overview

Explains common boat instrumentation like tachometer, temperature, oil pressure, voltmeter, and hour meters.

Electronic Speed Control System

Details the optional electronic speed control system, including MPH and RPM modes, and its operation.

Starting the Engine

Provides step-by-step instructions and warnings for starting fuel-injected engines, including ventilation and safety checks.

Shifting Transmission Procedure

Explains how to safely shift the transmission into forward, reverse, and neutral, emphasizing throttle position.

Stopping the Engine

Details the procedure for safely shutting down the engine, including returning throttle to idle and turning off the ignition.

Freezing Temperature Operation

Advises on protecting the cooling system from freeze damage when freezing temperatures are possible.

Operation in High Debris Areas

Recommends using a properly sized sea strainer to prevent debris from entering the cooling system.

Crusader Challenger Cruise Control System

Explains the optional cruise control system, including MPH and RPM modes for maintaining selected speeds.

Cruise Control Operation Modes

Details cancelling cruise set-point, resuming previous speeds, and exiting cruise mode properly.

Factors Affecting Engine Operation

Weight Distribution Effects

Explains how gear, passenger, and ballast weight affect boat handling and engine performance.

Boat Bottom Maintenance

Stresses the importance of a clean boat bottom for maximum engine performance and fuel economy.

Propeller Selection Guidance

Guides on selecting the correct propeller for optimal performance, engine life, and RPM range.

Engine Break-In and Initial Service

Engine Break-In Period

Provides detailed instructions and warnings for the first 25 hours of engine operation to ensure proper break-in.

25-Hour Engine Inspection

25-Hour Engine Inspection

Outlines recommended checks and maintenance tasks to be performed after the first 25 hours of operation.

Fuel Requirements

Gasoline Requirements

Specifies required unleaded gasoline octane rating and warnings about fuel quality and contamination.

Gasoline Containing Alcohol (Ethanol)

Advises on the acceptable use of E10 fuel and warns against methanol and fuels above E10, noting potential damage.

Oil Requirements

Engine Oil Recommendations

Provides recommended API classification, viscosity for various temperatures, and notes on synthetic oils.

Transmission and V-Drive Oil Requirements

Specifies the recommended ATF fluid for transmissions and synthetic lubricant for V-Drive units.

Engine Maintenance

Engine Maintenance Overview

Highlights the importance of regular maintenance and recommends dealer service for complex procedures.

Checking Engine Crankcase Oil

Provides detailed steps and cautions for checking engine oil level, emphasizing proper boat position and conditions.

Checking Transmission Fluid

Details how to check fluid levels for Challenger 80 Series Transmissions, including cold/warm checks and dipstick use.

Challenger Power-Plus V-Drive Transmission Maintenance

Explains the 'maintenance free' nature of V-Drive transmissions and fluid level checks.

Shift Cable Lubrication

Advises lubricating pivot points and exposed shift cables with SAE 30W-30 engine oil.

Electrical System Relay and Fuse Block

Identifies the fuse block and its components, explaining the function of fuses for critical engine systems.

Battery Maintenance and Safety

Provides warnings and guidelines for handling batteries, including connection and charging safety.

Battery Care and Electrical System Caution

Details battery care, warnings about open circuits, and cautions against adding unauthorized electrical components.

Fresh-Water Cooling System Zinc Anodes

Explains the location and function of sacrificial zinc anodes in the fresh-water cooling system for corrosion protection.

Checking Coolant Level

Provides instructions and warnings for checking the coolant level in the degas bottle, emphasizing engine temperature.

Flushing Cooling System (Sea-Water)

Details the procedure for flushing the sea-water section of the cooling system with fresh water to prevent buildup.

Testing Coolant Alkalinity

Explains how to test coolant alkalinity using litmus paper to determine if replacement is needed.

Draining Fresh-Water Cooling System

Guides on removing drain plugs/hoses to drain the fresh-water portion of the cooling system for maintenance.

Filling Fresh-Water Cooling System

Provides instructions for filling the fresh-water cooling system with antifreeze solutions (DEX-COOL, SIERRA) and proper mixing.

Cleaning Sea-Water Section of Heat Exchanger

Details how to clean the sea-water side of the heat exchanger to maintain cooling efficiency.

Fuel System Description

Describes the In-Tank High Pressure Fuel Pump System and the Fuel Control Cell (FCC) System components and operation.

Servicing the Fuel Control Cell (FCC)

Covers servicing the FCC, including frequency of draining and filter replacement warnings.

Draining the FCC Bowl

Provides steps for draining the FCC bowl, emphasizing safety precautions and proper disposal of contents.

Fuel Filter Element Replacement

Details the procedure for replacing the FCC fuel filter element, including safety warnings and part numbers.

Servicing Primary Fuel Pre-Filter

Explains how to replace the primary fuel pre-filter element, including frequency and safety precautions.

Priming Fuel System

Outlines the procedure for priming the fuel system by cycling the ignition key before starting the engine.

Flame Arrestor Maintenance

Describes how to check and clean the flame arrestor for blockages caused by dirt or foreign material.

Accessory Drive Belt Inspection and Replacement

Guides on inspecting the drive belt for condition and tension, and provides steps for replacement.

Supercharger Belt Replacement

Details the procedure for replacing the supercharger drive belt, including noting belt routing and tensioner use.

Servicing Raw Water Pump Impeller

Explains the service intervals and procedures for inspecting or replacing the raw water pump impeller.

Changing Engine Oil

Provides a step-by-step guide for changing engine oil and filter, including warnings about overfilling and proper procedure.

Engine Alignment

Explains the importance of proper engine alignment and the steps to achieve it, including checking coupling surfaces.

V-Drive Alignment Procedure

Details the specific steps for aligning the engine and V-Drive mounts, including mount removal and adjustment.

Offset and Angular Alignment Adjustment

Describes how to adjust engine mounts for offset and angular alignment using adjusting nuts and bolts.

Mount Adjustment and Alignment Checks

Details left/right engine adjustment and checking for angular misalignment using feeler gauges at intervals.

Specifications and Capacities

Engine Fluid Capacities

Lists engine crankcase oil capacity and notes on checking levels, emphasizing accurate measurement.

Transmission Fluid Capacities

Lists fluid capacities for Challenger transmissions and V-Drive units, specifying fluid types.

Filter Requirements

Lists required filter part numbers for oil, primary fuel, and FCC fuel filter elements.

Power-Plus V-Drive Lubricant

Specifies the part number for the required lubricant for Challenger Power-Plus V-Drive transmissions.

Maintenance Schedule

Maintenance Schedule Overview

Provides a comprehensive schedule of checks and services required at daily, 25-hour, 50-hour, 100-hour, and annual intervals.

Maintenance Schedule Details

Continues the maintenance schedule, detailing services for flame arrestor, hoses, cables, fuel filters, and transmissions.

Visual Inspection Guidelines

Advises on visually inspecting the engine for leaks, loose parts, and cosmetic damage to maintain appearance and prevent issues.

Engine Specifications

Engine Specifications Table

Presents detailed specifications for 5.7L, 6.0L/HO, and 6.2L SC engines, including displacement, bore, stroke, RPM, and pressures.

Engine Electrical, Timing, and Battery Specifications

Details electrical system, ignition timing, CAM retard, and battery rating specifications for different engine models.

Master Warning;Alarm Specifications

Lists specifications for coolant over-temperature, exhaust manifold water temp, and low oil pressure sensors, including DTC codes.

Tune-Up Specifications

Provides tune-up data including spark plug type/gap, ignition timing, firing order, and CAM retard for various engine models.

Out-of-Season Storage

Engine Storage Procedure

Outlines essential steps for storing the engine, including fuel stabilization, filter replacement, and cylinder fogging.

Draining Instructions

Provides detailed instructions for draining the sea-water section of the cooling system and removing the raw water pump impeller.

Battery Storage Guidelines

Offers instructions for storing batteries, including cleaning, filling, and periodic charging to prevent damage.

Out-of-Season Engine Warm-Up

Details the procedure for warming up the engine after cold weather storage to reduce condensation.

Recommissioning After Storage

Lists checks and procedures required to recommission the engine after a storage period before operation.

Troubleshooting Engine Issues

Engine Cranking and Starting Problems

Addresses issues like the engine not cranking or cranking but not starting, listing possible causes and corrective actions.

Engine Overheating and Temperature Issues

Covers causes and solutions for engine overheating, insufficient temperature, and low oil pressure.

Transmission and Performance Issues

Addresses transmission slipping, rough running engines, backfires, and general poor engine performance.

Water Flow Diagrams and Draining

5.7 L CES DDrive Crusader Challenger Draining

Illustrates drain locations for the 5.7L CES DDrive Crusader Challenger engine for winterization or draining purposes.

5.7 L CES VDrive Crusader Challenger Draining

Shows drain locations for the 5.7L CES VDrive Crusader Challenger, detailing points for winterization.

Salt Series 5.7 L CES DDrive Crusader Challenger Draining

Depicts drain locations for the Salt Series 5.7L CES DDrive, highlighting points for winterizing.

Salt Series 5.7 L CES VDrive Crusader Challenger Draining

Illustrates drain points for the Salt Series 5.7L CES VDrive Crusader Challenger, essential for winterizing.

6.0 L;6.0 L HO CES Direct Drive Draining

Shows drain locations for 6.0L/6.0L HO CES Direct Drive engines for winterization and raw water draining.

Heater Connections

Heater Water Return Connection

Details how to connect the water return line for the heater, specifying plug location on the circulation pump.

Heater Water Out Connection

Explains how to connect the water out line for the heater, noting the plug location on the intake manifold.

Instrumentation and Wiring Diagrams

Engine Harness Wiring Color Charts

Provides color charts for 2-pin, 8-pin, and 14-pin engine harness connectors, detailing circuit functions.

Service and Parts Literature

Obtaining Service and Parts Literature

Instructs on how to contact Crusader Challenger for detailed service and parts manuals, emphasizing providing engine model and serial number.

Forms and Documentation

Warranty Transfer Application

Provides the form and instructions for transferring the limited warranty to a subsequent purchaser.

Pre-Delivery Checklist

Lists essential checks to be performed by a technician prior to delivery to ensure proper installation and operation.

Ownership Change Notice

Provides a form for new owners to inform Pleasurecraft Marine of ownership changes for notification purposes.

Operation and Maintenance Log

Offers a logbook for recording maintenance activities, runs made, fuel consumption, and service dates.

Problem Notification Form

A form to report engine problems or request information, requiring detailed engine and owner identification.

Summary of Warranty Term Limits

Provides a concise outline of warranty coverage terms and hour limits for different engine models.

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