Volvo Penta 3.0 GS Operator'S Manual Download

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SPECIFICATIONS

Note:

Volvo Penta of the Americas, Inc., reserves the right to make changes in weight, construction, materials, or

specifications without notice or obligation.

3.0 GS ______________________________________________________________________

Battery size

12 volt with

360 Cold Cranking Amp (CCA) rating

Bore and stroke

4.00 x 3.60 inches (101.60 x 91.44 mm)

Carburetor

Adjustable idle circuit
Fixed main fuel jets
Electric choke

Charging system

65 amp alternator, with internal transistorized voltage regulator

Cooling system

Variable volume pump on engine
Recirculating pump on engine
Thermostatically controlled temperature

Cylinders (number)

4 in-line

Displacement

181 cubic inches (3.0 liters)

Firing order

1 – 3 – 4 – 2

Fuel filter (in fuel pump)

Volvo Penta P/N 3855104

Fuel filter location

Refer to photographs on pages 22 through 23.

Fuel type

Inside the U.S.: 89 octane (AKI) unleaded gasoline
Outside the U.S.: 93 octane (RON) unleaded gasoline

Full throttle operating range

4200 – 4600 RPM

Idle RPM (fixed)

600 – 750 RPM in forward gear

Ignition timing

Authorized Volvo Penta dealer service only

Oil capacity

Engine

Without filter: 3.5 quarts (3.3 liters)
With filter: 4 quarts (3.8 liters)

Drive unit

Approximately

2.2 quarts (2.1 liters)

Oil filter

Volvo Penta P/N 835440

Oil filter location

Refer to photographs on pages 22 through 23.

Oil type

Engine

DuraPlus™ Premium engine oil labeled for API service CE/SG

Drive unit

DuraPlus GL 5 synthetic gear lube

Power steering fluid

DuraPlus power steering fluid

Spark plugs

Volvo Penta P/N

3854399

Spark plug gap

0.045 inches (1.14 mm)

Spark plug installation torque

20 ft. lb. (27 N

•

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Summary of Contents for 3.0 GS

Page 1: ...1 OPERATOR S MANUAL 3 0 GS 4 3 GL Gi 5 0 GL Gi 5 7 GS GSi 7 4 Gi GSi 8 2 GSi DPX 385 415 ...

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Page 3: ..._____________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ It is very important that you obtain all serial numbers directly from serial number plates attached to product assem blies Check page 17 for the location of product...

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Page 5: ... Action Service VAS 17 Doing your own maintenance and repairs 18 Parts and accessories 18 Volvo Penta dealer network 18 Warranty information 18 2 PLUS 4 Extended Protection 19 FEATURES 21 Anodes sacrificial 32 Audible alarm 32 Engine systems 32 Cooling system 32 Fuel system 32 Exhaust system 33 Electrical system 33 Lubrication system 33 Steering system 33 Drive components 33 Emergency stop switch ...

Page 6: ...uge location 51 Shifting and controlling speed 51 Checking instruments 52 Special boating circumstances 52 Engine protection mode operation fuel injection systems 52 Shallow water operation 52 High altitude operation 52 Operating procedure for freezing temperatures 53 Salt water operation 53 Twin unit operation 53 Trailering your boat 53 Propeller selection 53 MAINTENANCE 55 Maintenance schedule 5...

Page 7: ...d level 70 Steering reservoir fluid level 70 Primary shaft spline and bearing lubrication 71 Tie rod twin installations only 71 Engine and drive service 71 Lubrication system 71 Engine crankcase oil 71 Checking engine oil level 72 Changing engine oil 72 Changing the oil filter 73 Drive components 73 Drive unit lubrication 73 External lubrication points 76 Anodes sacrificial anodes 76 Active corros...

Page 8: ...i GSi 8 2 GSi 91 DPX 385 DPX 415 92 APPENDIX A CERTIFIED ENGINES AND BSO NUMBERS 93 Certified engines 93 Bodensee Shiffahrts Ordnung BSO number 93 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 9: ...compasses personal family business and environmental values Environmental care in all operations from design to production distribution service and recycling is an integral part of the Volvo quality commitment towards customers employees and the community By embracing the environment as a core value Volvo demonstrates its understanding of the environmental impact its products have upon nature and ...

Page 10: ...le cruising This is because the propeller installed originally is frequently one that is designed to give maximum speed when the boat is new For this reason it is often advisable to reduce the propeller pitch by as much as an inch or more in order to counter the effects of the increase in overall weight encountered in normal cruising particularly in hotter climates Although this will reduce top sp...

Page 11: ... the safety of all passengers Make sure that all operators read this manual before operating the boat Show your passengers the location of emergency equipment and explain how to use it Be sure one of your passengers knows how to handle your boat in case of emergency Requirements for personal flotation devices life vests life preservers and other safety equipment vary depending on the type of boat ...

Page 12: ...ng your fuel delivery system in top condition Fuel vapor is volatile handle fuel with care Keep your boat and equipment neat and in top operating condition Carry a selection of spare parts for the engine Volvo Penta s on board kit contains a selection of essential items that a boat owner should carry at all times See your Volvo Penta dealer NEVER OPERATE THE BOAT IF YOU ARE UNDER THE INFLUENCE OF ...

Page 13: ... that a safety related defect is discovered on any of their products If you are not the original owner of this engine and drive please notify us at our address listed on page 85 or through an authorized Volvo Penta dealer about the change in ownership This is the only way we will be able to contact you if necessary This manual will alert you to certain things you should do very carefully If you do...

Page 14: ... intake before carrying out operations on the engine cooling system 10 Only start the engine in a well ventilated area If operating the engine in an enclosed space make sure your work area is well ventilated 11 Anticorrosion and antifreeze agents can be hazardous to health and to the environment Whenever you use these agents follow the manufacturer s instructions on the product packaging 12 Certai...

Page 15: ...s are designed and constructed to minimize the risk of fire and explosion Using non original Volvo Penta parts that do not meet the above standards can result in fire or explosion on board Damage caused by using non original Volvo Penta replacement parts will not be covered under any warranty provided by Volvo Penta 21 Fuel filter replacement should be carried out on a cold engine to avoid the ris...

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Page 17: ...e of such change When reference is made in this manual to a brand name number product or specific tool an equivalent product may be used in place of the product referred to unless specifically stated otherwise To avoid hazards equivalent products used must meet all current U S Coast Guard Safety Regulations and American Boat and Yacht Council ABYC standards All illustrations used in this manual ma...

Page 18: ...ired for maintaining a high standard of service Volvo Penta dealers and vendors must maintain a stock of original spare parts and accessories to cover most requirements of Volvo Penta owners When ordering a service or spare parts always quote the engine and drive reverse gear complete type designation and serial number You will find this infor mation on the engine product plate and on a decal on t...

Page 19: ...rotection plan which provides additional service benefits for a total of six years of coverage The 2 PLUS 4 program covers most repairs to Volvo Penta engines drives and transmissions and is fully transferable to second owners The extended protection plan provides mechanical coverage a towing allowance and optional accessories and trailer coverage It covers an extensive list of repairs with only a...

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Page 21: ...make sure that your Volvo Penta product stays in optimum running condition The important parts of each component are shown in the photographs on pages 22 through 31 Explanations of these parts and systems are described below the maintenance procedures are found in the Mainte nance section starting on page 55 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 22: ...22 3 0 GS Alarm and Fuse Detail 3 0 GS front view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 23: ...23 3 0 GS starboard view 3 0 GS port view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 24: ...24 4 3 GL 5 0 GL 5 7 GS front view Fuses and circuit breakers port view Fuses and circuit breakers starboard view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 25: ...25 4 3 GL 5 0 GL 5 7 GS port view 4 3 GL 5 0 GL 5 7 GS starboard view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 26: ...26 4 3 Gi 5 0 Gi 5 7 GSi front view Fuses and circuit breakers port view Fuses and circuit breakers starboard view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 27: ...27 4 3 Gi 5 0 Gi 5 7 GSi starboard view 4 3 Gi 5 0 Gi 5 7 GSi port view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 28: ...28 7 4 Gi 7 4 GSi 8 2 GSi front view Fuses and circuit breakers port view Fuses and circuit breakers starboard view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 29: ...29 7 4 Gi 7 4 GSi 8 2 GSi starboard view 7 4 Gi 7 4 GSi 8 2 GSi port view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 30: ...30 DPX 385 415 front view Fuses and circuit breakers port view Fuses and circuit breakers starboard view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 31: ...31 DPX 385 415 starboard view DPX 385 415 port view 7797286 Downloaded from www volvopenta com 19 05 2015 19 28 09 ...

Page 32: ...h galvanic and stray current corrosion For the added protection needed a galvanic isolator may be installed in the grounding or green wire between the boat and the shore power outlet on the dock The isolator will block DC flow but will permit the passage of AC flow If you are connected to an AC power source that is not equipped with a galvanic isolator you may need additional sacrificial anodes to...

Page 33: ...rication system components 1 Oil changes 2 Oil filter 3 Oil quality Steering system The steering system allows you to steer your boat in the direction you want to go You will need to take care of these steering system components 1 Remote control shift cable 2 Steering system cable 3 Power steering fluid Drive components ____________________________________________________________ Important drive c...

Page 34: ...situa tions normal engine operation is limited to 2500 RPM or less Above 2500 RPM the engine will exhibit poor running characteristics Use the oil pressure and water temperature gauges to verify a problem exists then check the engine for proper oil level and the water inlets for obstructions The low oil pressure engine overheat problem must be cor rected before the engine will return to normal ope...

Page 35: ...n beach range above idle speed or for prolonged periods of time may cause serious drive damage Digital trim instrument DP S This instrument displays a figure the angle of the drive to a stationary boat within a range Trim range Use trim range for maximum comfort under normal operation from start to maximum speed maximum range up to 5 Beach range Use beach range for operating at reduced speed in sh...

Page 36: ...ater leakage If there is obvious or suspected damage operate the boat at low RPM and take it to a Volvo Penta dealer for inspec tion Have necessary repairs made immediately Only operate your boat if absolutely necessary Operating a damaged unit could cause additional damage and could become very costly to repair Always check your boat and engine for damage Failure to inspect for damage may Result ...

Page 37: ... stainless steel propellers This propeller has custom cupped high rake blades to provide better bow lift and make boats plane quick and run fast a terrific choice for high performance boats Duoprop sterndrive propeller choices The propellers for the Duoprop drive units have application and diameter pitch identification symbols D0 D9 E2 E5 and F2 F9 The single number repre sents the diameter pitch ...

Page 38: ...hen you removed it and make sure that the propellers are not switched Duoprop drive unit Duoprop drive units have counter rotating propellers it is not necessary to change drive unit rotation The propellers operate in sets The forward propeller is left hand and rotates counter clockwise The rear propeller is right hand and rotates clockwise Propellers are installed in sets You may purchase the pro...

Page 39: ... If full throttle RPM is above the recommended operating range propeller s with higher pitch should be used To provide your boat with the best engine life fuel economy and performance select the correct propeller to allow the engine to run at full throttle in the recommended operating range Your Volvo Penta dealer will help you to choose the correct propeller s for your application Replace a damag...

Page 40: ...tton on the control lever has two functions Pressing the top half of the button moves the drive trim out while it the raises the boat s bow Pressing the bottom half of the button moves the drive trim in while it the lowers the boat s bow You must press a separate switch on the instrument panel to disconnect the catch so that the drive can be trimmed into the BEACH position Control lever with catch...

Page 41: ...roblems Check your phone user manual for more detailed instructions Using the remote diagnostic uplink system If you find that you are having a problem that requires technical assistance 1 Call Volvo Action Service toll free at 1 877 337 3682 then press the SEND button 2 The VAS coordinator will assist you 3 Go to data mode Press the VOICE DATA button on the bulkhead panel Press the END button on ...

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Page 43: ...piston rings are properly seated The engine may use more engine oil during the running in period than would otherwise be normal Check the oil level regularly and more frequently during the running in period Maintain oil level in the safe range between the ADD and FULL marks on dipstick Somewhat higher oil consumption is normal until the piston rings have seated If you have a problem getting a good...

Page 44: ...al two hour break in do not run the engine at any constant RPM for prolonged periods of time Next eight hours 1 During the next eight hours continue to operate at approximately throttle or less minimum cruising speed Occasionally reduce throttle to idle speed for a cooling period 2 During this eight hours of operation you may operate at full throttle for periods of less than two minutes Final ten ...

Page 45: ..._________________ After the break in period the engine can be operated at any RPM from idle to full throttle Cruising at 3600 RPM or less however saves fuel reduces noise and prolongs engine life Before starting_______________________________________________________________ Note Do not start the engine out of the water unless you have an optional flushing adapter Follow the adapter manufacturer s ...

Page 46: ...the key switch to START and hold until engine starts for no longer than ten seconds If the engine does not start let go momentarily then try again 3 As soon as engine starts release key to ON or RUN If the engine floods GL GS models 1 Disengage the shift mechanism 2 Move the remote control handle to FULL THROTTLE 3 Turn the key switch to START 4 As soon as the engine starts Return the remote contr...

Page 47: ...3 Turn the key switch to START 4 As soon as the engine starts Return the remote control handle to IDLE Turn the key to ON or RUN Move the remote control handle to FAST IDLE to warm up the engine Do not exceed 1000 RPM Gi GSi models Advance the control handle to throttle to clear a flooded engine In this throttle position with the engine speed below 400 RPM cranking speed the ECM turns off the fuel...

Page 48: ...s or other control cables to the steering cable Make sure deck combing and bulkheads allow for steering cable movement If the power steering system stops working it will feel harder to steer If this condition occurs look for pos sible causes and fix them if possible If the power steering system cannot be corrected on board proceed at a reduced speed You will be able to steer the boat but with incr...

Page 49: ...wn Position Operating in bow up position The bow up position is normally used for cruising running with a choppy wave condition or running at full speed In a full bow up position the boat may tend to self steer You may have to compensate with the steering wheel to keep the boat in a straight ahead path In this position the boat s bow will tend to raise clear of the water Excessive bow up trim will...

Page 50: ...ngine parts and propeller Any malfunction of the trim tilt system could result in a loss of impact protection Malfunction can also result in loss of reverse thrust capability If malfunction occurs see your authorized Volvo Penta dealer Power trim tilt switch operation Trimming and tilting the drive is done from a control switch mounted on the remote control or by using the switches on the dash Whe...

Page 51: ...NEUTRAL lock mechanism and move the shift handle forward Throttle movement will begin after the FORWARD gear engages 4 To go in REVERSE Actuate the NEUTRAL lock mechanism and move the shift handle rearward Throttle move ment will begin after the REVERSE gear engages 5 To go from FORWARD to REVERSE or REVERSE to FORWARD always pause at NEUTRAL and allow engine speed to return to idle Do not shift f...

Page 52: ... draft for shallow water running as long as you do not exceed 1000 RPM Exceeding 1000 RPM is not necessary It will only increase the boat wake and will not increase boat speed appreciably Exceeding 1000 RPM with the drive unit tilted could damage drive train components This type of damage is not covered by warranty Never attempt to plane the boat or exceed 1000 rpm with the drive unit in a partial...

Page 53: ...ning during close maneuvering or at slow speeds If only one engine is running water may be forced back through the underwater exhaust outlet and cause serious engine damage Do not attempt to plane the boat while operating on a single engine The propellers are selected for the boat to operate optimally with twin engines Operating with a single engine could cause engine damage Trailering your boat__...

Page 54: ...rating range e g laboring engine Install lower pitch propeller s 2 Allows engine RPM above the specified full throttle operating range e g overspeeding engine Install higher pitch propeller s IMPORTANT D series aluminum propeller sets are not recommended for use on Duoprop equipped boat and engine combi nations that are capable of speeds in excess of 43 MPH 35 knots F series stainless steel propel...

Page 55: ...ighten Function Adjust Check Lubricate Fill Replace Torque Weekly Anodes sacrificial Cooling system leakage Emergency stop switch clip and lanyard Fuel system leakage Oil engine crankcase Oil drive unit Safety equipment Shift system operation Steering reservoir fluid Steering system cable operation Monthly Battery and connections water level Emergency stop switch clip and lanyard Exhaust system ho...

Page 56: ...erioration Steering system cable operation Throttle cable damage and operation Dealer only Belt serpentine 3 0 GS all fuel injected models Carburetor adjustment as needed Engine alignment and mounting screws Exhaust manifold risers corrosion blockage Gimbal bearing PCV valve Shift system operation Universal joints Universal joint bellows Universal joint shaft splines Once per season or every 100 o...

Page 57: ...l as necessary 16 Check drive and transom shield anodes Clean or replace as necessary Off season storage preparations winterization _________________________________ Be sure to properly winterize your Volvo Penta equipment Engine or drive damage can result from ignoring simple preventive maintenance steps during autumn Winterizing gives you the assurance that your engine will run more reliably and...

Page 58: ...r ground it in some other manner This action prevents static electricity build up that could cause sparks and ignite fuel vapors Gasoline recommendations USE ONLY UNLEADED FUEL Maximum engine performance requires the use of lead free gasoline with the following minimum or higher octane specification Inside the U S R M 2 AKI 89 Outside the U S RON 93 If fuels with 89 AKI pump posted 93 RON octane n...

Page 59: ...m To prevent gum formation and corrosion in the fuel system use a fuel stabilizer in the gasoline if it has been in the tank for more than two weeks Fuel stabilizer is available from your Volvo Penta dealer EFI models Some marinas sell fuel with lead additives Do not use leaded fuel as it may plug the fuel injectors Fuel leakage can contribute to a fire and or explosion Frequently inspect nonmetal...

Page 60: ...engine is cranking or running If a pump does not function check the fuses and replace them if necessary See your Volvo Penta dealer if further service is required Do not run engine out of fuel or run the electric fuel pumps dry more than 20 seconds Running the electric fuel pumps dry will damage the fuel pumps Fuel filter All models have a fuel filter in the fuel line before the fuel pump IMPORTAN...

Page 61: ...causing a noisy fuel pump Operating the engine with a restricted filter may damage the pressure regulator or fuel pumps See your Volvo Penta dealer if the pump makes an unusual noise Carburetor fuel filter replacement 1 Turn off the engine 2 Disconnect the fuel line at the carburetor 3 Remove the fuel inlet nut gasket and screen 4 Clean the screen with solvent then allow it to dry 5 Reinstall the ...

Page 62: ...heavy duty 12 volt 650 CCA battery con structed for marine use 2 All other batteries must be heavy duty and constructed for marine use They can be either vented refillable maintenance free or deep cycle with a CCA or INCA rating 3 Use bolts and nuts to secure battery cables to the battery terminals Do not use wing nuts to secure battery cables even if they were supplied with the battery 4 Tighten ...

Page 63: ...intenance free batteries have special instructions Make sure to follow them carefully Battery electrolyte is a corrosive acid and should be handled with care If you spill or splash electrolyte on any part of the body immediately flush the exposed area with liberal amounts of water and seek medical attention as soon as possible Note It is important that the battery connections are correct The negat...

Page 64: ...ative terminal on the battery and the engine s positive cable must be attached to the positive terminal on the battery Use a 12 volt battery with the following specifications a minimum 650 Cold Cranking Amp CCA rating at 0 F 18 C 165 minutes reserve capacity rating at 89 F 27 C Fumes vented during battery charging may cause an explosion Do not expose battery to electrical sparks or an open flame D...

Page 65: ...Note If electrical connections are reversed or connections removed when the key switch is on or the engine is running the electrical system may be damaged immediately Spark plugs The following table provides spark plug part numbers spark plug gap and installation torque Spark plugs Spark plug Engine Model VP part number Spark plug gap installation torque Firing order 3 0 GS 3854399 0 045 in 1 14 m...

Page 66: ...ore wire in its resis tance to crossfire however it is more easily damaged than copper core For this reason pull on the spark plug boots to remove the spark plug wires rather than pulling on the wire insulation If the wire is stretched the core may be broken with no evidence of damage on the outer insulation If the core is broken it will cause misfiring In the case of wire damage it is necessary t...

Page 67: ...st be arranged between the distributor cap and spark plugs in the order of firing sequence If spark plug wires are not correctly installed misfiring or crossfiring will result Belt adjustments To prevent possible injury caused by someone inadvertently starting the engine remove the ignition keys from each starting location especially if the engine room engine compartment cannot be seen from variou...

Page 68: ... 4 Recheck belt tension Cooling system ______________________________________________________________ Volvo Penta engines have a thermostat controlled recirculating type cooling system 1 Cool water is drawn in through water intakes located on both sides of the lower gear case by a raw water pump mounted on the front of the engine 2 Water is pumped to the engine and routed by the circulating water ...

Page 69: ...ill prevent damage to cooling system compo nents if temperatures drop below freezing When draining the engine raise or lower the bow of the boat to position the engine in a level attitude This will provide for complete drainage of the block and manifold If the bow of the boat is higher or lower than the stern some water may be trapped in the block Engine raw water cooled 1 3 0 only Open the manifo...

Page 70: ...that they are not in optimum condition 2 Check steering system hoses for cracks leaks and wear Replace any hoses that you suspect are not in optimum condition 3 DPX only Check steering system hydraulic hoses for cracks leaks and wear Replace any hoses that you suspect are not in optimum condition Power trim tilt fluid level The power trim and tilt assembly contains an electric motor hydraulic pump...

Page 71: ...bricate the sterndrive yourself Instructions for SX drive unit lubrication are located on page 73 Instructions for DP drive unit lubrication are located on page 74 Instructions for DPX drive unit lubrication are located on page 75 If you have your Volvo Penta dealer lubricate the sterndrive make sure to take it to your dealer at the required inter vals as outlined in your maintenance schedule on p...

Page 72: ...te Do not allow the crankcase oil level to go below the ADD mark and do not fill above the FULL mark Overfilling results in high operating temperatures foaming air in oil loss of power and overall reduced engine life Changing engine oil Engine oil and the oil filter are important factors affecting engine life They affect ease of starting fuel economy combustion chamber deposits and engine wear Dra...

Page 73: ...ive unit damage Fully thread the dipstick into the hole then remove and check the oil level Make sure that the oil level comes to the top of the flattened portion of the dipstick The oil should be amber colored The oil will appear milky if any moisture is present No metal flakes should appear in the oil If moisture or metal flakes appear in the drive unit oil take the boat to your Volvo Penta deal...

Page 74: ... factory with Volvo Penta DuraPlus GL5 Synthetic gearcase lubricant This lubricant must be used when adding lubricant or refilling the drive unit Adding lubricant Fully thread the oil dipstick into the oil level hole in the drive unit to properly check the oil level An improper oil level may result in serious drive unit damage Each week check the oil level in the drive unit if possible without rem...

Page 75: ...before checking oil with the dipstick This will help ensure all air is purged from the oil cavity Leave the dipstick loose during the waiting period Lubricating the drive unit DPX The drive unit is filled at the factory with Volvo Penta DuraPlus GL5 Synthetic gearcase lubricant This lubricant must be used when adding lubricant or refilling the drive unit Adding lubricant Each week check the oil le...

Page 76: ...f the gimbal housing and at the front of the gearcase above the anti ventilation plate On the DPX drive only there are addi tional anodes at the back of the intermediate housing and on the steering cylinders Anodes are slowly eroded away by galvanic action and require inspection Additionally anodes that are subjected to frequent wetting and drying require periodic scraping with coarse emery cloth ...

Page 77: ...e rate of once every five seconds the demand for protection is very low If the light is flashing once per second the demand for protection is high and the system is operating at maximum capacity The Volvo Penta active corrosion protection system is designed to adequately protect one drive unit from galvanic corrosion Note This system will not provide protection from stray currents emitted by a mal...

Page 78: ...is is not done 4 Place the thrust bushing on the propeller shaft with the inner taper toward the gearcase to match the taper on the propeller shaft 5 Install the propeller onto the propeller shaft aligning splines and push the propeller onto the thrust bushing until the splines are exposed 6 Install the thrust washer on propeller shaft splines 7 Shift the remote control into REVERSE gear to lock t...

Page 79: ... components could result in loss of the propeller and damage to the drive unit the next time the boat is operated 1 Ignition switch must be OFF 2 Make sure the remote control is in FORWARD 3 Coat the full length of the propeller shaft with Volvo Penta propeller shaft grease Removal of the propeller will be difficult later if this precaution is not done 4 Install the front propeller 5 Install the f...

Page 80: ...t 4 Install the front propeller 5 Install the front propeller locking nut Use the special tool to tighten the nut to 37 52 ft lb 50 70 N m 6 Shift the remote control into REVERSE to lock the propeller shaft 7 Install the rear propeller 8 Install the rear propeller locking nut use a 30 mm socket Tighten the nut to 19 26 ft lb 25 35 N m 9 Install the locking screw Use the special tool to tighten the...

Page 81: ...clamps Fuel injector O rings injector fuel line pressure relief valve and caps fuel reservoir vent hose and cover gasket high pressure fuel pump mounting O rings fuel pressure regulator and fuel rails Your Volvo Penta product was designed to operate in a marine environment This can involve operating at high RPM for long periods in salt or brackish water in water laden with silt and minerals Substi...

Page 82: ...e and immediately relubricate all internal parts All electrical devices must also be dried and inspected for water damage 3 Frequently check engine compartment for gasoline fumes and excessive water accumulation In addition make sure that the water depth in the bilge is kept well below the flywheel housing Delay in completing the above actions may result in extensive engine damage 7797286 Download...

Page 83: ...See your Volvo Penta dealer Electrical system problem See your Volvo Penta dealer Boat overloaded Reduce or redistribute load Boat hull condition Clean boat hull Incorrect fuel octane Fill gas tank with proper fuel High shift effort Remote control box or shift cable See your Volvo Penta dealer Engine vibrates Propeller condition Check for damaged propellers Check for bent propeller shaft Look for ...

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Page 85: ...ts Manager etc Explain exactly what caused the problem and ask what action will be taken If the matter remains unresolved after a reasonable amount of time 2 Discuss the matter with the Dealer Principal usually the owner or co owner of the dealership Explain what took place in step 1 If the matter is not resolved within a reasonable amount of time 3 Contact the Consumer Affairs Department at Volvo...

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Page 87: ...uel pump Volvo Penta P N 3855104 Fuel filter location Refer to photographs on pages 22 through 23 Fuel type Inside the U S 89 octane AKI unleaded gasoline Outside the U S 93 octane RON unleaded gasoline Full throttle operating range 4200 4600 RPM Idle RPM fixed 600 750 RPM in forward gear Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter 3 5 quarts 3 3 l...

Page 88: ... the U S 89 octane AKI unleaded gasoline Outside the U S 93 octane RON unleaded gasoline Full throttle operating range 4200 4600 RPM Idle RPM GL 550 650 RPM in forward gear Gi 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter 4 quarts 3 8 liters With filter 4 5 quarts 4 3 liters Drive unit SX approximately 2 2 quarts 2 1 liters DP approximately 2...

Page 89: ...ane AKI unleaded gasoline Outside the U S 93 octane RON unleaded gasoline Full throttle operating range GL 4400 4800 RPM Gi 4600 5000 RPM Idle RPM fixed GL 4400 4800 RPM Gi 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter 5 quarts 4 7 liters With filter 6 quarts 5 7 liters Drive unit SX approximately 2 2 quarts 2 1 liters DP approximately 2 5 qu...

Page 90: ...nleaded gasoline Outside the U S 93 octane RON unleaded gasoline Full throttle operating range GS 4400 4800 RPM GSi 4600 5000 RPM Idle RPM fixed GS 550 650 RPM in forward gear GSi 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter 5 quarts 4 7 liters With filter 6 quarts 5 7 liters Drive unit SX approximately 2 2 quarts 2 1 liters DP approximately...

Page 91: ... the U S 93 octane RON unleaded gasoline Full throttle operating range Gi 4200 4600 RPM GSi 4800 5200 RPM Idle RPM fixed 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter 8 quarts 7 5 liters With filter 9 quarts 8 5 liters Drive unit SX approximately 2 2 quarts 2 1 liters DP approximately 2 5 quarts 2 4 liters Oil filter Volvo Penta P N 3850559 O...

Page 92: ...on pages 30 through 31 Fuel type Inside the U S 89 octane AKI unleaded gasoline Outside the U S 93 octane RON unleaded gasoline Full throttle operating range DPX 385 4800 5200 RPM DPX 415 4600 5000 RPM Idle RPM fixed 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter 8 quarts 7 5 liters With filter 9 quarts 8 5 liters Drive unit Approximately 2 06...

Page 93: ...f you are unsure of anything to do with your engine s function or maintenance Those of you who own or maintain a certified Volvo Penta engine must be aware of the following Service intervals and maintenance by Volvo Penta must be adhered to Only Volvo Penta genuine parts intended for certified engine may be used An authorized Volvo Penta service dealer must always service the ignition system ignit...

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Page 96: ...7797286 TX English 03 2000 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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