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PCM HO303 MPI - User Manual

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OWNER’S OPERATION
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MAINTENANCE MANUAL
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Table of Contents

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Summary

Introduction

Registration Information

Owner registration card and survey details.

3-Year Transferable Limited Warranty

Details of limited warranty coverage and owner obligations.

Federal;California Emission Control Warranty Statement

Explains emission control system warranty rights and responsibilities.

PCM Inboard Marine Engine General Emissions Warranty Coverage

Outlines coverage for emission control devices on PCM engines.

Safety Information

General safety warnings and hazard symbol definitions.

Replacement Parts

Guidance on using genuine PCM replacement parts.

Boating Responsibilities

Carbon Monoxide Hazard

Information on CO hazards and prevention measures.

Safe Boating Suggestions

Recommendations for safe operation and required equipment.

Water Wisdom

Tips for safe boating to ensure passenger safety.

Operation and Maintenance

Owner's responsibility for safety checks and maintenance schedules.

Rules of the Road

Explanation of channel buoy guide and horn signals.

Engine Identification

Engine Identification

Details on locating engine model and serial number.

Owner Identification and Registration Information

Guidance for recording owner and engine details.

Engine Model Identification; Advisory

Explanation of engine model code structure.

Electronic Fuel Injection Information

Electronic Fuel Injection System

Overview of EFI system components and sensors.

Operating Instructions

Engine Alarm System

Explanation of engine warning lamps and buzzers.

Instrumentation

Description of typical boat instrumentation gauges.

Electronic Speed Control (If Equipped)

Details on Digital Throttle Control and cruise systems.

Starting Engine (Fuel Injected Engines)

Procedure for starting fuel-injected engines safely.

Shifting Transmission

Instructions for shifting transmission between gears.

Stopping Engine

Procedure for safely shutting down the engine.

Freezing Temperature Operation

Measures to protect cooling system from freezing.

Operation in High Debris Areas

Recommendations for operating in areas with debris.

PCM Basic Cruise Speed Control System (Optional)

Operation of MPH and RPM cruise modes.

Cancelling the Cruise Set-Point

Procedure to cancel a set cruise speed.

Resume Mode

How to resume a previous cruise speed setting.

Exiting Cruise Mode

Steps to disengage cruise control properly.

Conditions Affecting Operation

Trim and Weight Distribution

Effects of boat trimming and weight on handling.

Boat Bottom

Importance of a clean boat bottom for performance.

Propeller Selection

Factors influencing propeller selection for optimal performance.

Engine Break-In Period

Engine Break-In Period

Guidelines for the initial 25 hours of engine operation.

25-Hour Engine Inspection

25-Hour Engine Inspection

Recommended maintenance after the first 25 hours.

Fuel Requirements

Gasoline Requirements

Specifications for octane rating and fuel types.

Gasoline Containing Alcohol

Information on using ethanol and methanol fuels.

Oil Requirements

Engine Oil Recommendations

Recommended oil types, viscosity, and additives.

Transmission and “V”-Drive Oil Requirements

Specifications for transmission and V-drive fluids.

Engine Maintenance

Engine Maintenance

General overview and recommendation for dealer service.

Checking Fluid Levels

Procedure for checking engine crankcase oil level.

Transmission Fluid

Checking fluid levels for PCM and Hurth transmissions.

PCM Power-Plus V-Drive Transmission

Maintenance for V-Drive transmissions.

Lubrication

Lubrication points for throttle and shift cables.

Electrical System Relay and Fuse Block

Description of the fuse block and panel fuse.

Battery

Safety precautions for handling and maintaining the battery.

Fresh-Water Cooling System Sacrificial Zinc Anode

Checking and replacing the zinc anode.

Checking Coolant Level

Procedure for checking engine coolant level.

Flushing Cooling System - Sea-Water Section

Instructions for flushing the sea-water cooling system.

Testing Coolant for Alkalinity

Procedure to test coolant alkalinity.

Draining Fresh-Water Portion of the Cooling System

Steps to drain the fresh-water cooling system.

Filling Fresh-Water Cooling System (Non-Catalyst and Half-System Applications)

Procedure for filling the fresh-water cooling system.

Filling Fresh-Water Cooling System (ZR409 CES; ZR450 CES Full-Fresh Applications)

Procedure for filling specific CES fresh-water systems.

Fuel System Description

Overview of the Fuel Control Cell (FCC) system.

Servicing the FCC

Procedure for draining the FCC bowl.

Filter Element Replacement, ENGINE OFF

Replacing the primary fuel pre-filter element.

Priming Fuel System

Steps to prime the fuel system after filter replacement.

Flame Arrestor

Checking and cleaning the flame arrestor.

Accessory Drive Belt

Inspection and replacement of the serpentine belt.

Drive Belt Inspection

Checking the condition and tension of drive belts.

Drive Belt Replacement

Procedure for replacing the drive belt.

Servicing Raw Water Pump Impeller

Maintenance for the raw water pump impeller.

Changing Oils

Procedure for changing engine oil and filter.

Engine Alignment

Importance and procedure for checking engine alignment.

V-Drive Alignment

Specific alignment procedures for V-Drive systems.

Engine Fluid Capacities

Table of engine and transmission fluid capacities.

Filter Requirements

Part numbers for various filters.

PCM Power-Plus V-Drive Lubricant

Part number for V-Drive lubricant.

PCM Basic Cruise Speed Control System

Part numbers for cruise control components.

Engine Specifications

PCM Master Engine Specifications - 2011

Technical specifications for 2011 PCM engines.

PCM Master Fuel Pressure Specifications - 2011

Fuel pressure specs for 2011 PCM engines.

PCM Master Warning;Alarm Specifications - 2011

Engine alarm and warning specifications.

Tune-Up Specifications

Spark plug, timing, and firing order details.

Out-of-Season Storage

Engine Storage

Procedures for preparing the engine for long-term storage.

Draining Instructions

Steps for draining cooling system and removing impeller.

Battery Storage

Guidelines for storing the boat battery.

Recommissioning After Storage

Steps to prepare the engine for use after storage.

Troubleshooting

Engine will not crank with the starter motor, or cranks slowly.

Diagnosing and resolving starter motor issues.

Engine Cranks - will not start or is hard starting.

Troubleshooting starting problems.

Engine Overheats

Causes and solutions for engine overheating.

Insufficient engine temperature

Diagnosing low engine operating temperature.

Engine oil pressure low

Troubleshooting low engine oil pressure.

Transmission slipping - erratic operation

Diagnosing and resolving transmission slipping.

Engine misses, runs rough and;or backfires

Troubleshooting engine misfires and rough running.

Poor engine or boat performance

Identifying causes of reduced engine or boat performance.

Water Flow Diagrams

Direct Drive Raw-Water Cooling System HO303; EX343

Diagram showing raw-water cooling flow for HO303/EX343 direct drive.

Vee Drive Raw-Water Cooling System HO303; EX343

Diagram showing raw-water cooling flow for HO303/EX343 Vee Drive.

Direct Drive Half-System HO303; EX343

Diagram showing half-system cooling flow for HO303/EX343 direct drive.

Vee Drive Half-System HO303; EX343

Diagram showing half-system cooling flow for HO303/EX343 Vee Drive.

Direct Drive CES HO303; EX343

Diagram showing CES direct drive cooling flow for HO303/EX343.

Vee Drive CES HO303; EX343

Diagram showing CES Vee Drive cooling flow for HO303/EX343.

Direct Drive Fresh-Water Cooling System ZR409; ZR450

Diagram showing fresh-water cooling flow for ZR409/ZR450 direct drive.

Vee Drive Fresh Water Cooling System ZR409; ZR450

Diagram showing fresh-water cooling flow for ZR409/ZR450 Vee Drive.

Direct Drive Full-Fresh ZR409 CES; ZR450 CES

Diagram showing full-fresh CES cooling flow for ZR409/ZR450 direct drive.

Vee Drive Full-Fresh ZR409 CES; ZR450 CES

Diagram showing full-fresh CES Vee Drive cooling flow for ZR409/ZR450.

Direct Drive Half-System ZR450 CES

Diagram showing half-system CES cooling flow for ZR450 direct drive.

Vee Drive Half-System ZR450 CES

Diagram showing half-system CES Vee Drive cooling flow for ZR450.

Heater Connections

Water Out

Procedure for connecting heater water out hose.

Water Return

Procedure for connecting heater water return hose.

Instrumentation Wiring Diagrams

2-Pin Wire Harness Color Chart

Color codes for 2-pin engine harness connectors.

8-Pin Wire Harness Color Chart

Color codes for 8-pin engine harness connectors.

Literature

Service

Information on obtaining detailed service manuals.

Parts

Information on obtaining parts manuals with exploded views.

Forms

PCM Warranty Transfer Application

Application for transferring PCM limited warranty.

Pre-Delivery Checklist

List of checks performed before engine delivery.

Summary of Warranty Term Limits

General outline of warranty terms by engine model year.

PCM Ownership Change Notice

Form to notify PCM of ownership change.

Operation and Maintenance Log

Logbook for recording maintenance and operations.

Problem Notification or Information Request Form

Form to report engine problems or request information.

Notes

PCM HO303 MPI Specifications

General IconGeneral
BrandPCM
ModelHO303 MPI
CategoryEngine
LanguageEnglish

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