Volvo Penta 3.0GL-B Operator'S Manual Download

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7741591 / 2003-12

Engine . . . . . . . . . . . . . . . . . .

DPX375-B(F), DPX420-B(F)

Bore and stroke . . . . . . . . . . . . . . . . .

107.95 x 111.00mm (4.250 x 4.370 inches)

Cylinders (number) . . . . . . . . . . . . . .

90° V-8

Displacement . . . . . . . . . . . . . . . . . .

496 cubic inches (8.1 liters)

Firing order . . . . . . . . . . . . . . . . . . . .

1 – 8 – 7 – 2 – 6 – 5 – 4 – 3

Full throttle operating range DPX375

4200 – 4600 RPM

Full throttle operating range DPX420

4600 – 5000 RPM

Idle RPM (fixed) DPX375 . . . . . . . . .

550 RPM

Idle RPM (fixed) DPX420 . . . . . . . . .

600 RPM

Fuel System

DPX375 / DPX420 . . . . . . . . . . . . . .

Port injection

Fuel pumps . . . . . . . . . . . . . . . . . . . .

Electric

Fuel filter . . . . . . . . . . . . . . . . . . . . . .

Volvo Penta Part no. 3852413

Fuel filter location . . . . . . . . . . . . . . .

Refer to photographs on features pages.

Fuel type . . . . . . . . . . . . . . . . . . . . . .

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

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

Electrical System

Charging system . . . . . . . . . . . . . . . .

12 volt 65 amp alternator, with internal transistorized voltage regulator

Battery size . . . . . . . . . . . . . . . . . . . .

12 volt with 650 Cold Cranking Amp (CCA) rating (135 minute reserve capacity)

CAUTION!

Do not use a deep cycle battery as the start battery.

Starter . . . . . . . . . . . . . . . . . . . . . . . .

12 volt 1.7kW output, planetary reduction gear

Ignition System

Distributorless . . . . . . . . . . . . . . . . . .

Crankshaft and camshaft triggered ignition sensors.

Ignition timing . . . . . . . . . . . . . . . . . .

10° BTDC fixed and non-adjustable, See Workshop Manual for procedure.

Spark plugs . . . . . . . . . . . . . . . . . . . .

Volvo Penta Part no. 3861326

Spark plug gap . . . . . . . . . . . . . . . . .

1.52 mm (0.060 inches)

Spark plug installation torque . . . . . .

30 N•m (22 ft. lb.)

Cooling system

Raw water pump . . . . . . . . . . . . . . . .

Crankshaft mounted variable volume flexible impeller pump

Recirculating pump . . . . . . . . . . . . . .

Fixed impeller belt driven pump on engine

Thermostat . . . . . . . . . . . . . . . . . . . .

64°C (140°F) Volvo Penta part no. 3853983

-BF . . . . . . . . . . . . . . . . . . . . . . . . . .

Closed cooling heat exchanger mounted on engine.

Thermostat . . . . . . . . . . . . . . . . . . . .

76°C (170°F) Volvo Penta Part no. 875788

Oil capacity

Engine without filter . . . . . . . . . . . . .

8 quarts (7.5 liters)

Engine with filter . . . . . . . . . . . . . . . .

9 quarts (8.5 liters)

Drive unit DPX-A . . . . . . . . . . . . . . . .

2.6 liters (2.7 quarts)

Oil filter . . . . . . . . . . . . . . . . . . . . . . .

Volvo Penta Part no. 3850559

Oil filter location . . . . . . . . . . . . . . . .

Refer to photographs on features pages.

Oil type

Engine . . . . . . . . . . . . . . . . . . . . . . . .

DuraPlus™ Heavy Duty Synthetic engine oil, or suitable pure synthetic oil altenative

with the minimum API service raing SJ

Drive unit . . . . . . . . . . . . . . . . . . . . . .

DuraPlus SAE 75W/90 API service GL 5 synthetic gear oil

Power Trim system . . . . . . . . . . . . . .

Duraplus Trim fluid Volvo Penta Part no. 3851039

DPX Steering fluid U.S. . . . . . . . . . . .

Steering fluid Part no. 1141640

Specifications

7741591 - Downloaded from www.volvopenta.com 12/03/2014 09:32:39

Summary of Contents for 3.0GL-B

Page 1: ...OPERATOR S MANUAL Engine Models 3 0GL B C 4 3GL A 4 3GXi A B F 5 0GL A B 5 0GXi A B F 5 7GL A B 5 7Gi A B F 5 7GXi B C F 8 1Gi B F 8 1GXi A F DPX375 A DPX420 A ...

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Page 3: ...eration 46 Operating after break in period 46 Before starting 47 Starting the engine cold start 47 Starting the engine warm start 48 Stopping the engine 49 Operating remote controls 49 Side mount control 49 Top mount control 49 Steering system operation 50 Twin unit steering 50 Power trim and tilt operation 51 Power trim operation 51 Determining the proper trim 51 Operating in bow up position 52 O...

Page 4: ...vice 76 Lubrication System 77 Engine crankcase oil 77 Drive components 78 Drive unit lubrication SX 78 Anodes sacrificial anodes 84 Active corrosion protection system 85 Propeller care 86 Propeller replacement SX 87 Propeller replacement DP S 88 Propeller replacement DPX 89 Boat bottom 90 Engine alignment 90 Replacement parts 90 Bottom painting 90 Engine submersion 90 Specifications 92 3 0GS B 3 0...

Page 5: ...ing or long hair can get caught in rotating parts and cause This owner s manual contains information you need to operate your boat engine and drive safely Check that you have the cor rect manual for your engine and drive This manual also contains a considerable amount of informa tion concerning the engine and drive model identification pre ventive maintenance recommendations fuel and oil recom men...

Page 6: ...and negative battery leads are correctly installed on the corresponding terminal posts Incorrect installation can result in serious damage to elec trical equipment 16 Always use protective goggles when charging and handling batteries Battery electrolyte contains sulfuric acid which is highly corrosive If battery electrolyte comes into contact with unprotected skin wash it off immediately using ple...

Page 7: ...es personal family business and environmental values Environmental care in all operations from design to produc tion 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 environ mental impact its products have upon nature and the s...

Page 8: ...uising particularly in hotter climates Although this will re duce top speed somewhat overall ride conditions will improve and you should achieve greatly enhanced acceleration In considering the influence of weight it is worth remembering that fiberglass boats absorb a significant amount of water into their hulls while left afloat for any length of time and so become progressively heavier Another n...

Page 9: ...es where you can refuel on your planned course Tell friends or relatives about your route that is file a float plan Safety equipment Rescue and emergency items such personal flotation de vices and signal rockets Make sure all passengers know where these items are Replacement parts Proper tools Basic safety rules of boating Shut off the engine when people who are in the water come near the boat Pro...

Page 10: ...on to boat operation and surrounding condi tions A boat traveling at a speed of approximately 70 M P H 60 knots covers about 101 feet 30 meters in 1 second The fast er you go the quicker things will happen High speed driving requires a lot of water and a good distance from possible haz ards Always allow for adequate reaction time Always reduce speed when visibility is reduced for whatever reason W...

Page 11: ...__________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ It is very important that you obtain all serial numbers directly from serial number plates attached to product assemblies Check features page for the location ...

Page 12: ...y be delayed until the warranty and registration form is on file at Volvo Penta Product references illustrations and specifica tions All information illustrations and specifications contained in this manual are based on the latest product information available at the time of printing Volvo Penta of the Americas Inc re serves the right to make changes at any time without notice in specifications an...

Page 13: ...all toll free 1 877 33 PENTA Doing your own maintenance and re pairs If you plan to do your own maintenance and repairs on your Volvo Penta products you should purchase a set of service manuals that pertain to your particular engine and drive Keep in mind however that there are certain tasks that should only be performed by your Volvo Penta dealer He has the tools expertise and most current inform...

Page 14: ...ber You will find this information on the engine product plate and on a decal on the valve cover Always take your Volvo Penta product to an authorized Volvo Penta servicing dealer for repair Our dealers have the knowl edge factory trained technicians and special tools to take care of any necessary repairs Ideally take your product back to your selling dealer he also knows you and your equip ment F...

Page 15: ... since delay of warranty claims can occur if no proof of the deliv ery date can be provided 2 PLUS 4 Extended Protection In addition to our factory warranty owners may purchase Volvo Penta s exclusive 2 PLUS 4 Extended Protection 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 transmissi...

Page 16: ...14 7741591 2003 12 Notes 7741591 Downloaded from www volvopenta com 12 03 2014 09 32 39 ...

Page 17: ...s are found in the Maintenance section Features Circuit breakers and fuses 4 3GL A 5 0GL A 5 0GL B 5 7GL A 5 7GL B 4 3GXi A 5 0GXi A 5 7Gi B GXi A 1 2 2 3 4 3 0GS B 3 0GS C 4 3GXi B F 5 0GXi B F 5 7Gi B F 5 7GXi C F 8 1Gi B F 8 1GXi A F DPX375 B F DPX420 B F 4 2 1 1 40 Amp Harness Fuse 2 Spare Fuse 3 7 5 Amp Fuel Pump Fuse 4 50 Amp Circuit Breaker Power Trim Pump 5 15 Amp Ignition Fuel Fuse 6 20 A...

Page 18: ...10 Circuit Breaker and Fuses 11 Oil Dipstick Engine 12 Oil Filter 13 Fuel Pump and Filter 14 Spark Plugs and Wires 15 Anodes 16 Water Intake 17 Exhaust Overheat Sensor 18 Exhaust Riser 19 Engine Flush 20 Water Drain Exhaust Manifold 21 Propeller 22 Oil Drain Sterndrive 23 Water Drain Engine 24 Exhaust Manifold 3 0 GS B 1 2 3 4 5 6 7 8 10 7741591 Downloaded from www volvopenta com 12 03 2014 09 32 ...

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Page 20: ... 10 Circuit Breaker and Fuses 11 Oil Dipstick Engine 12 Oil Filter 13 Fuel Pump and Filter 14 Spark Plugs and Wires 15 Anodes 16 Water Intake 17 Exhaust Overheat Sensor 18 Exhaust Riser 19 Engine Flush 20 Water Drain Exhaust Manifold 21 Propeller 22 Oil Drain Sterndrive 23 Water Drain Engine 24 Exhaust Manifold 1 2 4 5 6 7 8 10 3 0 GS C 7741591 Downloaded from www volvopenta com 12 03 2014 09 32 3...

Page 21: ...19 7741591 2003 12 Engine cover removed for clarity 3 11 12 13 14 15 17 19 23 20 18 21 21 9 9 3 0 GS C 7741591 Downloaded from www volvopenta com 12 03 2014 09 32 39 ...

Page 22: ...l Pump 14 Propeller s 15 Oil Dipstick Drive 16 Steering Cable 17 Starter 18 Exhaust Overheat Sensors 19 Audible Alarm 20 Exhaust Riser 21 Exhaust Manifold 22 Cooling Water Drain Manifold 23 Water Drain Engine 24 Spark Plugs 1 2 3 5 6 7 8 9 10 11 4 23 30 12 18 18 19 29 4 3GL A 5 0GL A B 5 7GL A B 25 Anodes 26 Raw Water Intake 27 Oil Drain Sterndrive 28 Oil Filter 29 Oil Fill Engine 30 Engine Flush ...

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Page 24: ...11 Raw Water Pump 12 Fuel Filter 13 Fuel Pump 14 Propeller s 15 Oil Dipstick Drive 16 Steering Cable 17 Starter 18 Exhaust Overheat Sensors 19 Audible Alarm 20 Exhaust Riser 1 3 5 6 7 8 9 10 11 4 12 18 18 19 29 13 2 5 21 Exhaust Manifold 22 Water Drain Manifold 23 Water Drain Engine 24 Spark Plugs 25 Anodes 26 Raw Water Intake 27 Oil Drain Sterndrive 28 Oil Filter 29 Oil Fill Engine 30 Engine Flus...

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Page 26: ...13 Fuel Pump 14 Propeller s 15 Oil Dipstick Drive 16 Steering Cable 17 Starter 18 Exhaust Overheat Sensors 19 Audible Alarm 20 Exhaust Riser 4 3GXi B 5 0GXi B 5 7Gi B 5 7GXi C 1 3 5 6 7 8 9 10 11 4 12 18 18 19 13 2 5 21 Exhaust Manifold 22 Water Drain Manifold 23 Water Drain Engine 24 Spark Plugs 25 Anodes 26 Raw Water Intake 27 Oil Drain Sterndrive 28 Oil Filter 29 Oil Fill Engine 30 Engine Flush...

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Page 28: ...12 Fuel Filter 13 Fuel Pumps 14 Engine flush connector 15 Oil Dipstick Drive 16 Steering Cable 17 Starter 18 Exhaust Overheat Sensors 19 Audible Alarm 20 Engine flush Raw water drain valve 21 Heat Exchanger 22 Water Drain Manifold 23 Water Drain Engine 24 Spark Plugs 25 Anodes 26 Raw Water Intake 27 Oil Drain Sterndrive 28 Oil Filter 29 Oil Fill Engine 30 Coolant Fill 3 1 2 4 5 6 7 8 9 10 11 12 13...

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Page 30: ...ick Engine 10 Cooling Water Drain Exhaust Manifold 11 Engine Oil Cooler 12 Engine Flush Engine Drain 13 Anodes 14 Raw Water Intake 15 Propellers 16 Oil Drain Sterndrive 17 Oil Filter 18 Power Steering Fluid Fill 19 Power Steering Pump 20 Serpentine Belt 21 Raw Water Pump 22 Fuel Pumps 23 Fuses 24 Flame Arrestor 25 Alternator 26 Oil Fill Engine 26 8 1Gi B 8 1GXi A 7741591 Downloaded from www volvop...

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Page 32: ...uel Filter 9 Oil Dipstick Engine 10 Cooling Water Drain Exhaust Manifold 11 Engine Oil Cooler 12 Engine flush drain 13 Anodes 14 Raw Water Intake 15 Propellers 16 Oil Drain Sterndrive 17 Oil Filter 18 Power Steering Fluid Fill 19 Power Steering Pump 20 Serpentine Belt 21 Raw Water Pump 22 Fuel Pumps 23 Fuses 24 Flame Arrestor 25 Alternator 26 Oil Fill Engine 7741591 Downloaded from www volvopenta ...

Page 33: ...31 7741591 2003 12 16 2 1 23 3 8 9 5 13 4 7 6 14 15 10 17 1 2 5 11 14 10 12 DPX 375 DPX420 7741591 Downloaded from www volvopenta com 12 03 2014 09 32 39 ...

Page 34: ...er 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 handle the added corrosion poten tial Audible alarm The audible alarm will alert you to unacceptable or dangerous ly low oil pressure high water temperature levels and or h...

Page 35: ...system an odes power trim tilt universal joint and propellers Emergency stop switch An emergency stop switch may be a feature of your Volvo Penta powered boat Volvo Penta highly recom mends that you have an emergency stop switch in stalled in your boat To properly use this feature attach the lanyard securely to your clothing Do not at tach the lanyard to clothing that will tear away before the lan...

Page 36: ... off the engine then restart it NOTE If the problem continues contact your near est Volvo Penta dealer and have the engine checked Instruments Before operating your Volvo Penta product familiarize yourself with the instruments supplied with your boat Some boats may not have Volvo Penta instruments Read the boat s owner s manual to become familiar with the instruments used Engine instruments Tachom...

Page 37: ...re water depth is uncertain Also use this range when you launch and take your boat out of water onto a trailer ramp Lift range Use lift range for lifting the drive to its maximum angle howev er this range cannot be used during boat operation Use this range when you are transporting your boat The power trim has an automatic stop feature which cuts off the current when the drive reaches STOP STOP is...

Page 38: ...ION Operating in beach range or lift range will cause sig nificant loss of maneuverability Operating in beach range above idle speed or for prolonged periods of time may cause serious drive damage LED display Certain LEDs display at certain times for the digital trim instru ment 1 Flashes red within the range above 41 2 Constant red within the range of 6 to 40 3 Constant green within the range of ...

Page 39: ...e immediately Closely inspect the boat and drive unit especially the transom shield assembly that contains steering sys tem components Check the engine compartment for water leakage If there is obvious or suspected damage operate the boat at low RPM and take it to a Volvo Penta dealer for inspection Have necessary repairs made immediately Only operate your boat if absolutely necessary Operating a ...

Page 40: ...way the boat is used Ask your Volvo Penta dealer to assist you in choosing a propeller that is right for your needs SX sterndrive propeller choices 1 Aluminum propellers Volvo Penta s aluminum propellers are die cast and dynami cally balanced Die cast propeller blades are thinner than sand cast blades which means less cavitation greater effi ciency and longer service life All aluminum propellers a...

Page 41: ...ects of salt water The unique design of the Duoprop with its two counter rotating propellers is very important in achieving optimum performance Note D5 D6 and D7 propellers are recommended for speeds below 40 MPH For installations where D series propellers are not recom mended F series stainless steel propellers should be used 2 F series stainless steel propellers A stainless steel Duoprop set is ...

Page 42: ...o attach the shift linkage in the same position it was in when 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 counterclock wise The rear propeller is right hand and rotates clockwis...

Page 43: ...erating Range 3 0GS B 3 0GS C 4200 4600 RPM 4 3GL A 4200 4600 RPM 4 3GXi A 4 3GXi B 4400 4800 RPM 5 0GL A 5 0GL B 4400 4800 RPM 5 0GXi A 5 0GXi B 4600 5000 RPM 5 7GL A 5 7GL B 4400 4800 RPM 5 7Gi A 5 7Gi B 4600 5000 RPM 5 7GXi B 5 7GXi C 4600 5000 RPM 8 1Gi B 4200 4600 RPM 8 1GXi A 4600 5000 RPM DPX375 B 4200 4600 RPM DPX420 B 4600 5000 RPM If full throttle RPM is below the recommended operating r...

Page 44: ...le mount controls do not have a NEUTRAL lock but do have a NEUTRAL detent CAUTION Your boat should be equipped by the manufacturer with a remote control with protection to prevent start ing in gear Use only a remote control unit with start in neutral only feature This feature can prevent injury resulting from the propeller turning unexpect edly or the boat moving suddenly The shift mechanism on al...

Page 45: ...h so that the drive can be trimmed into the BEACH position Control lever with catch button single installa tion A switch on the control lever allows you to trim the drive Pressing the switch up moves the drive trim out while it the raises the boat s bow Pressing the switch down moves the drive trim in while it the lowers the boat s bow The catch button disconnects a catch so that the drive can be ...

Page 46: ...44 7741591 2003 12 Notes 7741591 Downloaded from www volvopenta com 12 03 2014 09 32 39 ...

Page 47: ...0 0 F 18 C 32 F 0 C SAE 20W 20 Below 0 F 18 C SAE 10W 32 F 0 C above SAE Viscosity Chart Recommended SAE 30 Volvo Penta DuraPlus Synthetic Motor Oil P N 3851230 7 U S and Canada Only If the rec ommended oil is not available use pure synthetic multi vis cosity oil The 3 0GS B and 3 0GS C may use a mineral base oil at first service change interval However switching between mineral based oils and syn...

Page 48: ...perate correctly All gauges instruments and alarms operate correctly Steering system operates correctly Engine ignition timing and idle RPM are within speci fications Power trim system operates correctly Stop the engine and Change engine oil and oil filter Change fuel water separator filter Clean seawater strainer if equipped Check fluid levels and fluid condition in sterndrive or inboard transmis...

Page 49: ...ock if so equipped 4 Make sure that there are no fuel engine coolant or oil leaks 5 Check engine oil level 6 Switch on the main switches if so equipped 7 Insert the key into the ignition switch Turn the key one step to the right to switch on engine system voltage and instrumentation 8 Make sure that you have enough gasoline 9 Lower the drive unit make sure the water intakes are sub merged There sh...

Page 50: ...e the control handle to the NEUTRAL detent position 2 Turn the key switch to START and hold until the engine starts but for no longer than 10 seconds If the engine does not start let go momentarily then try again 3 As soon as the engine starts release the key to ON or RUN CAUTION Never leave the key in the ON position with the en gine not running This could damage the engine Never turn the key to ...

Page 51: ...UTRAL Top mount control To disengage the shift mechanism 1 Push in and hold shift disengagement button 2 Move control handle FORWARD to increase throttle The shift mechanism will automatically engage when the control handle is returned to NEUTRAL Stopping the engine 1 Move the remote control handle to NEUTRAL 2 Let engine return to idle 3 Turn ignition key to OFF CAUTION Do not stop the engine at ...

Page 52: ...oat but with increased effort See your authorized Volvo Penta dealer as soon as possible to correct your power steering system At slow speeds no wake your boat may tend to wander This is normal and may be overcome by anticipating bow direction and correcting with steering wheel A slightly higher throttle and trim setting may also lessen the tendency to wander Changing weight distribution aft to fo...

Page 53: ...ale 6 to 10 of the trim gauge indicates the bow down positions Determining the proper trim The effect of the maximum bow up and bow down positions will be similar for most boats The bow position best for your operating conditions could be at any trim setting between the maximum bow up and bow down positions The boat will be properly trimmed when the trim angle provides the best boat performance fo...

Page 54: ...operating at slow planing speeds and running against a choppy wave condition In the fully bow down 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 go deeper into the wa ter If the boat is operated at high speed and or against high waves the bow of the boat will plow in...

Page 55: ...d 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 When using the da...

Page 56: ...ve the shift handle forward Throttle move ment will begin after the FORWARD gear engages 4 To go in REVERSE Actuate the NEUTRAL lock mecha nism 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 FOR WARD always pause at NEUTRAL and allow engine speed to return to idle Do not shift from FORWARD to RE VERSE wh...

Page 57: ...pressure is approximately 21 71 psi 150 500 kPa Water Temperature Gauge For all models except 8 1Gi B and 8 1 GXi temperature should be between 155 F 175 F 68 C 79 C For 8 1Gi B and 8 1GXi A the range should be between 138 F 158 F 59 C 70 C Voltmeter Operating charge is approximately 14 volts When engine is stopped voltage is approximately 12 volts Operation 7741591 Downloaded from www volvopenta ...

Page 58: ...is mode is entered 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 crankcase for proper oil level and the water inlets for obstructions The low oil pressure engine overheat exhaust overheat problem must be corrected before the...

Page 59: ...ble horsepower the engine RPM at full throttle should be in the specified full throttle operating range Refer to Specifications pages for full throttle RPM range Propellers that allow full throttle operation at the upper end of the RPM range provide faster planing time for water skiing or similar activities Propellers that place full throttle operation RPM in the middle of the range provide improv...

Page 60: ...ls replace as necessary or once every two years whichever comes first Maintenance Function Adjust Check Lubricate Fill Replace Tighten Torque 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 conn...

Page 61: ...er pump Oil engine crankcase Oil drive unit Oil filter engine Propeller and shaft Remote control shift cable damage Spark plugs Spark plug wires boots deterioration Steering system cable operation Throttle cable damage and operation Belt serpentine 3 0GS all fuel injected models Carburetor adjustment as needed Engine alignment and mounting screws Exhaust manifold risers corrosion blockage Gimbal b...

Page 62: ...e assurance that your engine will run more reliably and eco nomically in the springtime Volvo Penta recommends that you have your Volvo Penta dealer winterize your engine and drive Your dealer will pro vide the proper servicing and maintenance to ensure that your equipment is treated and stored properly Exhaust System Engine exhaust system Periodically inspect the engine exhaust system Check for D...

Page 63: ... today contain alcohol Two commonly used alcohol additives are Ethanol ethyl alcohol and Methanol methyl alcohol See your boat s owner s manual to see if the boat s fuel system is compatible with alcohol blended fuels If it is your engine may be operated using gasoline blended with no more than 10 Ethanol meeting the minimum octane specification CAUTION Do not use any gasoline that contains METHAN...

Page 64: ...stment If operational problems occur see your Volvo Penta dealer Electronic fuel injection Gi GXi The electronic fuel injection EFI fuel metering system delivers the correct amount of fuel to the engine under all operating conditions The EFI system is controlled by a microprocessor and requires no periodic maintenance or adjustment If opera tional problems occur see your Volvo Penta dealer Flame a...

Page 65: ... off immediately EXPLOSION AND FIRE ARE AN EXTREME DANGER 8 Clean up the bilge until fuel cannot be detected by smell NOTE A loud whining noise at idle may be due to a restricted fuel filter 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 rep...

Page 66: ...cables to the battery terminals Do not use wing nuts to secure battery cables even if they were supplied with the battery 4 Tighten all battery connections Loose battery connections may cause damage to the engine s electrical system 5 Service electrical components only while the engine is off Be careful when identifying positive and negative battery cables and terminals If you touch the wrong term...

Page 67: ...ttery cables WARNING Do not expose the battery to electrical sparks or an open flame Do not use jumper cables and a booster battery to start the engine Remove the battery from the boat to recharge Do not recharge the battery in the boat The service life of your battery depends largely on how it is maintained Keep batteries dry and clean Oxidation or dirt on the bat tery and battery terminals may c...

Page 68: ...tructed for marine use They can be either vented refillable maintenance free or deep cycle with a CCA or MICA rating Refer to Specifi cations pages for the correct battery sizes 2 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 3 Loose battery connections can cause damage to the engine s ...

Page 69: ...g terminals are fully seated on the spark plugs When spark plug leads are removed be sure they are replaced in the correct firing order see the table DANGER Avoid abusive handling that could crack the spark plug s ceramic body Damaged spark plugs can emit external sparks that could ignite any fuel vapors in the engine compartment Do not operate engine if spark plug boots or high tension leads are ...

Page 70: ...park plugs have a wet or oily deposit dip them in a decreasing solvent and dry thoroughly with com pressed air Oily plugs will cause the cleaning compound to pack in the shell Carefully follow the instructions of the manu facturer of the cleaner being used Clean each plug until the interior of shell and entire insulator is cleaned Avoid excessive blasting 7 Examine interior of plug in good light R...

Page 71: ...N when using a belt tension gauge If the belt is too tight excessive belt and bearing wear can occur If it is too loose slippage can occur resulting in belt wear poor circulating pump alternator and power steering operation 2 Belt tension should be checked after 10 hours of service and every 5 hours thereafter Circulating pump pulley Midpoint Midpoint Alternator pulley Power steering pump pulley A...

Page 72: ...Volvo Penta engines have a thermostat controlled type cool ing 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 circulat ing water pump through the cooling system 3 A thermostat inside the engine determines the amount of water to be taken in rec...

Page 73: ...f flush adapter Connect a garden hose to the connector with the supplied adapter NOTE The hose connection adapter supplied with the engine may not work in all geographic lo cations If you need an adapter other than the one supplied contact your Volvo Penta dealer for the correct adapter for you location Maintenance 2 1 21168 Caution Do not run the engine during the flushing procedure Water is not ...

Page 74: ...e heat exchanger approxi mately three revolutions 2 Twist the heat exchanger cover and gasket 2 in either direction and allow the water to completly drain from the system 3 After the heat exchanger is drained retighten the cover bolt to 27 N m 20 lb ft 4 Loosen the hose clamp 3 on the raw water inlet hose and remove the hose from the raw water pump 5 Allow all the water to drain and reinstall the ...

Page 75: ... suspect 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 sus pect are not in optimum condition Maintenance 7741591 Downloaded from www volvopenta com 12 03 2014 09 32 39 ...

Page 76: ... damage Do not allow contaminants to enter the reservoir when check ing or filling the oil level Primary shaft spline and bearing lubrication The primary universal joint shaft splines and bearings must be lubricated each year and whenever the drive unit is removed This procedure requires the removal of the drive unit there fore your Volvo Penta dealer should do it An ideal time to have this done i...

Page 77: ...k tube using the special fitting provided on the tube This special fitting is provided so that the oil does not have to be drained into the bulge 4 Withdraw oil with a suction pump NOTE You may purchase either a manual or an elec tric suction pump from any marine supply store or from your Volvo Penta dealer 5 Dispose of used oil according to any applicable federal state and local environmental reg...

Page 78: ... unit lubrication are found later in this manual Instructions for DP drive unit lubrication are found later in this manual Instructions for DPX drive unit lubrication are found later in this manual If you have your Volvo Penta dealer lubricate the sterndrive make sure to take it to your dealer at the required intervals as outlined in your maintenance schedule Maintenance 7741591 Downloaded from ww...

Page 79: ...y chart to select the SAE viscosity that matches the temperature range in which you expect to operate Recomended SAE 30 Volvo Penta DuraPlus Synthetic Mo tor Oil P N 3851230 7 U S and Canada If the recomended oil is not available use pure synthetic multiviscosity oil The 3 0GS B may use a mineral base oil at first service change interval However switching between mineral based oils and synthetic b...

Page 80: ... unit dam age 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 dealer...

Page 81: ...st to prevent excessive oil loss then the oil drain plug 5 Tighten oil level and drain plugs securely 6 Install the rear cover and tighten screws securely If you cannot fill the drive unit through the oil drain plug you can fill the drive by trimming it up a few degrees and filling it through the oil level plug Reinstall the oil level plug and place the drive in the run down position Remove the di...

Page 82: ...e 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 dealer If the oil level is low add only enough lubricant to bring the oil level within the full range of the dipstick Improper oil level may result in serious damage to the drive unit You should completely drain and refill the drive unit at least once per...

Page 83: ...e drive trimming it up a few degrees and filling through the oil level plug 6 Reinstall the oil level plug and place the drive in the run down position Remove the dipstick and check the oil level Reinstall the dipstick and tighten securely 7 Install the propellers refer to Propeller care 8 Install the rear cover and tighten screws securely 9 Check the oil level with the dipstick oil must appear on...

Page 84: ... 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 dealer If the oil level is low add only enough lubricant to bring the oil level within the full range of the dipstick Improper oil level may result in serious damage to the drive unit You should completely drain and refill the drive unit at least once per season Drainin...

Page 85: ...Penta DuraPlus GL5 Synthetic gearcase lubricant 9 When filled to the proper level install the oil fill plug and tighten it securely 10 Lower the drive and check the oil level with the dipstick 11 If necessary add oil through the dipstick hole 12 Make sure the fill and drain plug seals are not leaking 13 Install the rear cover and tighten screws securely Maintenance 7741591 Downloaded from www volv...

Page 86: ...es sories kit The accessories kit also includes o rings oils washers seals and bellows Replacing sacrificial anodes 1 Inspect anodes every 14 days or more frequently if used in extremely salty water If an anode is 2 3 its original size 1 3 eroded replace it NOTE If you use a stainless steel propeller additional sacrificial anodes may be required to handle the added corrosion potential 2 Remove the...

Page 87: ...a dealer The protection system s control box has a small LED indicator light that blinks once every one to five seconds to show the sys tem is operating properly If the light blinks at the rate of once every five sec onds 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 a...

Page 88: ...zes damage to drive unit and engine If the rubber hub should begin to slip it can be easily replaced at an authorized Volvo Penta dealer or propeller service station WARNING Protect your hands from the sharp edges of the pro peller blades Wear gloves whenever you remove or replace a propeller Do not attempt to hold propellers by hand when you remove or install propellers and propeller nuts Serious...

Page 89: ...ne 4 Place the thrust bushing on the propeller shaft with the in ner 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 the propelle...

Page 90: ...all all 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 Instal...

Page 91: ...CAUTION Failure to install all components may 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 Coat the full length of both propeller shafts with Volvo Penta propeller shaft grease It will be difficult to remove propel lers later if this precaution is not done 3 Make sure the remote control is in FORWARD to lock the pro...

Page 92: ... relief valve and caps fuel reservoir vent hose and cover gasket high pressure fuel pump mounting O rings fuel pressure regu lator 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 Substituting automotive or generally supplied parts and hard ...

Page 93: ...l 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 Check fuel supply for water contamination If gasoline is old or if water is present drain fuel tank and flush with fresh gasoline and change fuel filters Engine runs erratically Fuel filters Replace filters See your Volvo ...

Page 94: ...ming 2 ATDC special tool Volvo Penta part no 885163 required Spark plugs Volvo Penta Part no 3854399 Spark plug gap 0 045 inches 1 14 mm Spark plug installation torque 27 N m 20 ft lb Cooling system Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3853799 Oil capacity Engi...

Page 95: ...85163 required Spark plugs Volvo Penta Part no 3861632 Spark plug gap 0 060 inches 1 50 mm Spark plug installation torque 27 N m 20 ft lb Cooling system Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 Oil capacity Enginewithout filter 4 quarts 3 8 liters Engine wi...

Page 96: ...BTDC service mode required Spark plugs Volvo Penta Part no 3861632 Spark plug gap 1 50 mm 0 060 inches Spark plug installation torque 27 N m 20 ft lb Cooling system Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 GXi BF Closed cooling heat exchanger mounted on eng...

Page 97: ...ed Ignition timing 10 BTDC Spark plugs Volvo Penta P N 3861632 Spark plug gap 0 060 inches 1 50 mm Spark plug installation torque 27 N m 20 ft lb Cooling System Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 Oil capacity Engine without filter 5 quarts 4 7 liters ...

Page 98: ...ired Spark plugs Volvo Penta P N 3861632 Spark plug gap 0 060 inches 1 50 mm Spark plug installation torque 27 N m 20 ft lb Cooling System Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 Oil capacity Engine without filter 5 quarts 4 7 liters Engine with filter 6 q...

Page 99: ... GXi B 10 BTDC service mode required Spark plugs Volvo Penta Part no 3861632 Spark plug gap 1 50 mm 0 060 inches Spark plug installation torque 27 N m 20 ft lb Cooling system Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 GXi BF Closed cooling heat exchanger moun...

Page 100: ...hes non magnetic feeler gauge required Ignition timing 12 BTDC Spark plugs Volvo Penta part no 3861632 Spark plug gap 0 060 inches 1 50 mm Spark plug installation torque 27 N m 20 ft lb Cooling System Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 Oil capacity En...

Page 101: ...tool Volvo Penta part no 885163 required Spark plugs Volvo Penta part no 3861632 Spark plug gap 0 060 inches 1 50 mm Spark plug installation torque 27 N m 20 ft lb Cooling System Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 Oil capacity Engine without filter 5 ...

Page 102: ...ce mode required Gi B GXi C 10 BTDC service mode required Spark plugs Volvo Penta Part no 3861632 Spark plug gap 1 52 mm 0 060 inches Spark plug installation torque 27 N m 20 ft lb Cooling system Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 71 C 160 F Volvo Penta part no 3856961 Gi BF GXi CF Closed ...

Page 103: ...aft triggered ignition sensors Ignition timing 10 BTDC fixed See Workshop Manual for procedure Spark plugs Volvo Penta Part no 3861326 Spark plug gap 1 52 mm 0 060 inches Spark plug installation torque 30 N m 22 ft lb Cooling system Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Thermostat 64 C 140 F Volvo Penta...

Page 104: ... and camshaft triggered ignition sensors Ignition timing 10 BTDC fixed and non adjustable See Workshop Manual for procedure Spark plugs Volvo Penta Part no 3861326 Spark plug gap 1 52 mm 0 060 inches Spark plug installation torque 30 N m 22 ft lb Cooling system Raw water pump Crankshaft mounted variable volume flexible impeller pump Recirculating pump Fixed impeller belt driven pump on engine Ther...

Page 105: ...artment manager at the dealership e g Service Manager Parts Manager etc Explain exactly what caused the problem and ask what action will be taken 2 Discuss the matter with the Dealer Principal usually the owner or co owner of the dealership Explain what took place in step 1 3 Contact the Consumer Affairs Department at Volvo Penta of the Americas Inc 1300 Volvo Penta Drive Chesapeake VA 23320 Phone...

Page 106: ...our engine s function or maintenance Those of you who own or maintain a certified Volvo Penta en gine 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 ignition timing and the fuel injection system...

Page 107: ...7741591 Downloaded from www volvopenta com 12 03 2014 09 32 39 ...

Page 108: ...7741591 English 12 2003 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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