Volvo Penta 3.0GLP-C Owner'S Manual Download Page 124

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Technical Data

120

VPA 7743722 English 10-2004

Notes

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7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

Summary of Contents for 3.0GLP-C

Page 1: ...OPERATOR S MANUAL 3 0GLP C 4 3GL D 4 3GXi E 4 3GXi EF 5 0GL E 5 0GXi E 5 0GXi EF 5 7Gi E 5 7Gi EF 5 7GXi F 5 7GXi FF 8 1Gi F 8 1Gi FF 8 1GXi E 8 1GXi EF ...

Page 2: ...zu finden Ce manuel d instructions peut être commandé en français Vous trouverez un bon de commande à la fin du manuel d instructions Este libro de instrucciones puede solicitarse en español El cupón de pedido se encuentra al final del libro Den här instruktionsboken kan beställas på svenska Beställningskupong finns i slutet av instruktionsboken Questo manuale d istruzioni può essere ordinato in l...

Page 3: ... 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 the shared urban a...

Page 4: ... 436 5153 http www volvopenta com Volvo Action Service North America P O Box 26113 Greensboro North Carolina 27402 6113 Toll Free 877 33 PENTA Phone 336 393 4966 http myactionservice com English VAS_Penta asp World wide Dealer Locator http dealerlocator penta volvo se zone asp 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 5: ...20 Instrumentation 21 Instrument Panel 21 Audible Alarm 22 Emergency Stop Switch 22 Checking Instruments 23 Oil Pressure 23 Engine Coolant Temperature 23 Voltage Charge 23 Engine Protection Mode 24 Engine Control Module ECM 24 Master Slave Arrangement 25 Power Trim Tilt 25 Trim Instruments 26 Analog Trim Instrument 26 Optional Digital Trim Instrument 27 LED Display 27 Other Instruments 27 Trim Til...

Page 6: ... Adjustments 81 Serpentine Belt Engines 81 V Belt Engines 82 V Belt Tension 82 Power Steering Pump Belt 83 Alternator Belt 83 Cooling System 84 Raw Water System 84 Closed Cooling System F Series 84 Engine Overheating Gi GXi only 84 Engine Overheating All other Models 85 Engine Flush 85 Draining the Cooling System 86 Raw Water Cooled Engines 86 Draining the Closed Cooling System 87 8 1 Liter Engine...

Page 7: ...correctly performed operations could result in personal injury damage to property or harm the engine Read the operator s manual carefully before operating or servicing the engine If anything is unclear please contact your Volvo Penta dealer for assistance In the operator s manual warning texts have the following priority DANGER Failure to comply with a danger symbol will result in serious injury o...

Page 8: ...dangers and risks associated with carrying out certain activities High Pressure Fluid or gas may be eject ed under a great deal of pressure causing damage to metals fabrics or human tissue Corrosive Fluids gases or solids that can damage metals fabrics or human tissue through decay Toxic Gases or other airborne corrosives that can damage human tissue cause ill health or endanger life Poisonous Flu...

Page 9: ...the con trol position that work on the engine is being carried out Approaching or working on an engine that is running is dangerous Loose clothing hair fingers or a dropped tool can be caught in the rotating parts of the engine and cause serious personal injury We recom mend that all servicing with the engine running be un dertaken by an authorized Volvo Penta workshop Lifting the Engine To ensure...

Page 10: ...d and highly vola tile Incorrect connection of the battery can cause a spark which would be sufficient to cause an explosion Do not disturb battery connections when starting the en gine spark risk and do not lean over batteries Always ensure that the positive and negative battery leads are correctly installed on the corresponding ter minal posts Incorrect installation can result in serious damage ...

Page 11: ...r re moving a plug or engine coolant line from a hot en gine open the filler cap slowly and release coolant system pressure gradually otherwise steam or hot coolant can spray out Note that the coolant may still be hot and can cause burns Lubrication System Hot oil can cause burns Avoid skin contact with hot oil Ensure that the lubrication system is not under pressure before commencing work on it N...

Page 12: ...re engaging ahead or astern Never drive near bathers or in areas where people could be in the water Avoid trimming an out board drive too much as steering will be severely re duced Emergency Stop Switch We recommend that you install and use an emergen cy stop switch accessory especially if your boat can travel at high speeds The emergency stop switch acts as a safety breaker and stops the engine i...

Page 13: ...nstead Try disassembling opening or in any other way changing the setup of the cover as well If you suspect that your boat exhibits this station wag on effect please contact your Volvo Penta dealer for help in achieving the best solution for your boat WARNING Do not run the engine while there are people located on or near the swim platform and transom DANGER DO NOT tow anyone using wa ter sports e...

Page 14: ...s and so on Tell your passengers and crew where the safety equipment is stored and how to operate it Make sure you are not the only person on board who knows how to start the boat and operate it safely Planning Your Trip Everyone wants to have a problem free and pleasant time when they take their boat out To help you do this we have provided a pre journey checklist below Take extra time to check t...

Page 15: ...gh speed operation requires an experienced opera tor who has mastered handling of high performance boats It is advisable that you learn the boat s behavior before you take passengers on board Inform your passengers about your boat s characteristics and the maneuvers you intend to do Use the boat s perform ance with due consideration and care When operating at high speeds remember that other boater...

Page 16: ...Safety Information 12 VPA 7743722 English 10 2004 Notes 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 17: ...ny changes such as increased fuel consumption exhaust smoke Adapt speed and distance to avoid wash and noise disturbing or injuring animal life moored boats jetties etc Leave islands and harbours in the same condition as you want to find them Remember to always leave hazardous waste such as waste oil coolant paint and wash residue flat batter ies and other toxic disposables at a suitable disposal ...

Page 18: ...ust always be carried out by an authorized Volvo Penta workshop The engine must not be modified in any way except with accessories and service kits approved by Volvo Penta No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken Seals may only be broken by authorized person nel Otherwise the general instructions contained in this Operator s Manual concerning oper...

Page 19: ...lly at maximum revolutions per minute RPM Load Condition Speed of Planing Hull The overall weight of the boat is another important factor in performance Any increase in boat weight will slow down the boat speed particularly on boats with planing and semi planing hulls For example a new boat tested with fuel and water tanks only half filled and without any load can easily drop 2 to 3 knots in speed...

Page 20: ...Introduction 16 VPA 7743722 English 10 2004 Notes 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 21: ...e delay of warranty claims can oc cur if no proof of the delivery date can be provided Please contact your Volvo Penta dealer if you have not received a copy of Warranty Information North America PN 7796733 and a customer copy of the warranty card Volvo Action Service VAS Volvo Action Service VAS is a consumer breakdown service available 24 hours each day 365 days per year If your engine breaks do...

Page 22: ...f the exhaust manifold The label depicting the serpentine belt configuration is typically mounted on a flat surface located on the side of the alternator automatic tensioner bracket or on the power steering pump reservoir The California Emission sticker is located on the engine cover 3 0GL Engines Above port engine mount on side of engine block 4 3GL Engines On port front face of cylinder head 5 0...

Page 23: ...eing stolen Engine Decal Product Designation A Serial No B Product No C Engine Plate Product No A Type B Serial No C Transom Shield Plate Product No A Type B Ratio C Serial No D Drive Product No A Type B Ratio C Serial No D Transom Assembly Drive Unit Stickers Product Designation A Model No B Serial No C NOTE The Transom Assembly Drive Unit Stickers shown above should be located on the Engine Deca...

Page 24: ...urchase all Volvo Penta replacement parts acces sories coolants and lubricants from an authorized Volvo Penta dealer The dealer has needed parts in stock for routine maintenance as well as the informa tion needed to order special parts and accessories for you Only authorized Volvo Penta dealers may pur chase genuine parts and accessories directly from the factory Volvo Penta does not sell direct l...

Page 25: ...rating temperature for all engines except 8 1 Gi GXi is 155 178 F 68 81 C and 135 158 F 57 70 C for the 8 1 Gi GXi Engines with closed cooling systems will typically run about 30 F 17 C higher 3 Oil Pressure Gauge Indicates the engine oil pressure Normal operating oil pressure should be ap proximately 18 psi 124 kPa minimum at 2000 RPM on a warm engine Lower oil pressure is normal and should be ex...

Page 26: ...top switch also called a safety break er may be a feature of your boat Use of this switch is highly recommended To properly use this feature at tach the lanyard to clothing that will NOT tear away before the lanyard is pulled from the switch to stop the engine If the lanyard is too long shorten it by knotting or looping it DO NOT cut and re tie the lanyard Using this switch is simple and should no...

Page 27: ...pt 8 1 Gi GXi is 155 178 F 68 81 C and 135 158 F 57 70 C for the 8 1 Gi GXi Engines with closed cooling systems will typically run about 30 F 17 C higher Your engine is equipped with an engine coolant and exhaust temperature acoustic alarm1 CAUTION If engine coolant or exhaust tem perature is too high Idle the engine shift to reverse and then to forward Idle the engine for 2 3 minutes and shut off...

Page 28: ...ny load or with the drive in neutral the engine will exhibit surging NOTE Continuing to run the engine in this mode without correcting the cause may result in further engine damage Use the oil pressure and water temperature gauges to verify a problem exists then inspect the engine crank case for proper oil level and check the water inlets for obstructions The low oil pressure engine overheat probl...

Page 29: ... other engine will follow suit Power Trim Tilt Your Volvo Penta sterndrive is equipped with a power trim tilt system as standard equipment The power trim tilt allows you to change the angle of the drive unit from the helm Changing the angle of the drive unit in relation to the boat bottom is called trimming Trim ming provides these benefits Improves acceleration to planing Keeps the boat on plane ...

Page 30: ...d in shallow water where 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 however this range cannot be used during boat operation Use this range ONLY when you are transporting your boat CAUTION Operating in beach range or lift range will cause significant loss of man...

Page 31: ... range will cause significant loss of maneu verability 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 instrument 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 2 to 5 4 Constant green within the ra...

Page 32: ...ERSE You are backing up You trailer your boat You launch your boat NOTE Impact damage is more likely to occur when you are in a turn where side loads are placed on the drive unit If you strike a solid object Throttle back and shut off the engine immedi ately Closely inspect the boat and drive unit espe cially the transom shield assembly that contains steering system components Check the engine com...

Page 33: ...idle speed F Drive forward gear engaged for forward move ment ahead R Drive reverse gear engaged for backward movement astern T Engine speed control NOTE The engine can be started only if the drive is in neutral Shifting from Neutral To move the remote control lever from the neutral de tent position depress the throttle lock 3 then move the control lever in the desired direction Disengaging the Sh...

Page 34: ...OTE If your boat is equipped with a non Volvo Penta remote control system ask your deal er how to properly operate it IMPORTANT Carefully check function of all con trol and engine systems before leaving the dock 1 Move control handle 1 to the neutral detent idle position Check in front and behind boat for people or obstructions before shifting 2 To go forward Move the shift handle forward from neu...

Page 35: ...es a possible problem in the shift system If you suspect there is a problem see your Volvo Penta dealer as soon as possible for proper diag nosis and required service or adjustment Contin ued operation could result in damage to the shift mechanism and loss of shift and throttle control that could result in personal injury Cruising Speed Operating the engine at wide open throttle WOT should be avoi...

Page 36: ...astic cover that shields the remote control mechanism 4 Using a screwdriver adjust the friction brake screw 2 as necessary Turning the screw clock wise increases brake effect while turning it coun ter clockwise provides lighter lever action 5 Reinstall the plastic cover and remote control lever Top Mount Remote Controls 1 Make sure the engine is turned off by removing the key from the ignition swi...

Page 37: ...trimmed into the BEACH and LIFT positions Press this button and the center button at the same time Remote Control Lever The control button on the control lever has two func tions Pressing the top half of the button moves the drive trim out while raising the boat s bow Pressing the bottom half of the button moves the drive trim in while lowering the boat s bow You must press a separate switch on th...

Page 38: ...vidual adjustment of the drive trim Pressing the switches up moves the drive trim out while raising the boat s bow Pressing the switches down moves the drive trim in while lowering the boat s bow The catch buttons 9 optional disconnect a catch so that the drives can be trimmed into the BEACH and LIFT positions 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 39: ...blower and run as recom mended by the boat manufacturer Frequently check boat s bilge area for gasoline fumes 2 Check the bilge for excessive water accumula tion Always keep the bilge clean and dry CAUTION The water level in the boat s bilge will increase when you operate your boat at a high in cline before you reach planing speed Excessive water in the bilge can cause engine damage 3 Open the fue...

Page 40: ...TRAL 7 Repeat priming if necessary CAUTION Too much priming may flood the en gine If the engine fails to start after a few at tempts there may be a problem that needs to be addressed See your authorized Volvo Penta dealer for service Gi GXi Models 1 Move the control handle to the NEUTRAL detent position 2 Turn the ignition switch to START II and hold for no longer than ten seconds or until engine ...

Page 41: ...sition 2 Turn the ignition switch to START II and hold for no longer than ten seconds or until engine starts If the engine does not start let go momentarily then try again 3 As soon as engine starts release key to ON or RUN I CAUTION Never leave the key in the ON I po sition with the engine not running Never turn the key to START II when the engine is running Ei ther situation could damage the eng...

Page 42: ...rease throttle The throttle lock and gear shift release mechanism will automatically re engage when the control handle is returned to the NEUTRAL position Method 2 To disengage the gear shift mechanism on remote controls without a throttle lock 1 Push in and hold gear shift release button 2 2 Move control handle FORWARD to increase throttle The gear shift release mechanism will automatically re en...

Page 43: ... be able to steer the boat but with increased effort See your authorized Volvo Penta dealer as soon as possible to correct your pow er steering system At slow speeds no wake your boat may tend to wan der This is normal and may be overcome by anticipat ing bow direction and correcting with steering wheel A slightly higher throttle and trim setting may also lessen the tendency to wander Changing wei...

Page 44: ...or boat speed and when there is a change in water or boating conditions Locate passengers and equipment in the boat so that the weight is balanced fore and aft and side to side Trimming will not cancel an unbalanced load To operate the trim push and hold the switch bow up or bow down until the desired bow position is reached The trim may be operated at any boat speed or at rest Avoid operating the...

Page 45: ...el eration onto plane 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 water If the boat is operated at high speed and or against high waves the bow of ...

Page 46: ...ING To avoid possible contact with the propellers never use the drive unit as a ladder or as a lift to board the boat Never board at the rear of the boat when the engine is running even if the engine is operating in neutral Personal injury could result from contact with rotating engine parts and propellers Any malfunction of the trim tilt system could result in a loss of impact protection Malfunct...

Page 47: ...in the lower gear unit are submerged at all times Proceed at slow speed and lower drive unit immediately when deeper water is reached CAUTION Be very careful when operating in shallow water the intakes may pick up mud sand underwater vegetation or other sub merged debris This may lead to overheating and engine damage High Altitude Operation Volvo Penta EFI engines have programmed altitude compensa...

Page 48: ...it and spray it with anticorrosion spray Before trailering your boat on the road check the ground clearance of the drive unit When trailering the drive unit may be in the up or down position There must be at least 15 inches 38 1 cm clearance be tween the lower gear unit and the ground If the clear ance is less than 15 inches 38 1 cm raise the drive unit NOTE Be very careful when you back out of dr...

Page 49: ...y B Fuel Pump Relay C Ignition Relay D Spare Relay E Spare Fuses 15 20 Amp F1 20 Amp Instrument Panel Accessory 4 3GXi E 4 3GXi EF 5 0GXi E 5 0GXi EF 5 7Gi E 5 7Gi EF 5 7GXi F 5 7GXi FF 8 1Gi E 8 1Gi EF 8 1GXi D 8 1GXi DF EFI Engines 22872 F2 20 Amp Instrument Panel Accessory F3 15 Amp Ignition Fuel Fuse F4 15 Amp Engine Control Module ECM Fuse F5 20 Amp Spare Accessory Fuse F6 15 Amp EVC Fuse F7 ...

Page 50: ... 9 Raw Water Pump 10 Raw Water Outlet 11 Raw Water Inlet 12 Circulation Pump 13 Distributor 14 Engine Raw Water Flush 15 Spark Plugs 16 Oil Filter 17 Fuel Pump and Filter 18 Oil Siphon Tube 19 Starter 20 Oil Dipstick 21 Exhaust Riser 22 Exhaust Overheat Sensor 23 Exhaust Manifold Water Drain 24 Engine Raw Water Drain 25 Exhaust Manifold 1 Optional 7743722 Downloaded from www volvopenta com 13 05 2...

Page 51: ...VPA 7743722 English 10 2004 47 Features 22879 22880 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 52: ...Belt 12 Power Steering Fluid Fill 13 Power Steering Pump 14 Power Steering Belt 15 Raw Water Pump 16 Raw Water Outlet 17 Raw Water Inlet 18 Fuel Filter 19 Water Circulation Pump 20 Engine Raw Water Flush 21 Fuel Pump 22 Distributor 23 Spark Plugs 24 Engine Raw Water Drain 25 Starter 26 Exhaust Manifold Water Drain 27 Exhaust Manifold 28 Oil Filter 29 Intake Manifold Drain Plug1 1 4 3 GL Only 77437...

Page 53: ...VPA 7743722 English 10 2004 49 Features 22876 22877 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 54: ...utomatic Belt Tensioner 12 Serpentine Belt 13 Power Steering Fluid Fill 14 Power Steering Pump 15 Raw Water Pump 16 Raw Water Outlet 17 Raw Water Inlet 18 Water Circulation Pump 19 Fuel Pump High Pressure 20 Fuel Pump Low Pressure 21 Fuel Filter 22 Exhaust Riser 23 Spark Plugs 24 Engine Raw Water Flush 25 Engine Raw Water Drain 26 Starter 27 Exhaust Manifold Water Drain 28 Exhaust Manifold 29 Knoc...

Page 55: ...VPA 7743722 English 10 2004 51 Features 22887 22888 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 56: ...er Pump 14 Raw Water Outlet 15 Raw Water Intake 16 Water Circulation Pump 17 Fuel Pump High Pressure 18 Fuel Filter 19 Fuel Pump Low Pressure 20 Engine Raw Water Flush 21 Circuit Breaker and Fuses 22 Spark Plugs 23 Oil Dipstick Engine 24 Engine Raw Water Drain1 25 Starter 26 Exhaust Manifold Water Drain 27 Exhaust Manifold 1 The engine raw water drain plug on the 8 1 Liter engines is a Metric M14 ...

Page 57: ...VPA 7743722 English 10 2004 53 Features 22893 22894 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 58: ...Gi EF 5 7GXi FF 22889 1 Engine Coolant Fill Cap 2 Engine Coolant Reservoir 3 Raw Water Pump 4 Raw Water Inlet 5 Raw Water Outlet 6 Heat Exchanger Drain Cap 7 Heat Exchanger 8 Heat Exchanger Anode 18658 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 59: ...i EF 22891 1 Engine Coolant Fill Cap 2 Engine Coolant Reservoir 3 Water Circulation Pump 4 Raw Water Pump 5 Raw Water Outlet 6 Raw Water Inlet 7 Heat Exchanger Drain Cap 8 Heat Exchanger 18658 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 60: ...Features 56 VPA 7743722 English 10 2004 SX M Sterndrive 22896 1 Oil Fill 2 Trim Sender 3 Anodes 4 Raw Water Intake 5 Oil Drain 6 Propeller 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 61: ... English 10 2004 57 Features DP S Sterndrive 22895 1 Oil Fill 2 Trim Sender 3 Anodes 4 Raw Water Intake 5 Oil Drain 6 Rear Propeller 7 Front Propeller 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 62: ...Features 58 VPA 7743722 English 10 2004 Notes 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 63: ...1 GXi D 3869264 835440 3851230 3587597 3862228 8 1 GXi DF 3869265 835440 3851230 3831426 3862228 23179 23171 23172 1 23184 23185 3 0 GLP C 3869250 3862567 3851857 3854261 3854260 4 3 GL D 3869251 3862567 3858997 3854311 3854331 4 3 GXi E 3869252 3862567 3858997 3858977 3859019 4 3 GXi EF 3869253 3862567 3858997 3858977 3859019 5 0 GL E 3869254 3862567 3858996 X2 3862014 3854548 5 0 GXi E 3869255 3...

Page 64: ...8891 3868892 3868893 3868894 3868895 3868896 3868911 3868912 3868913 3868914 3851128 3854130 Zn 3855610 Mg 3586461 Al 3855411 Zn 3855412 Mg 3863193 Al 3854127 23244 23245 23247 SX DP S 3868889 3868890 3868891 3868892 3868893 3868894 3868895 3868896 3868911 3868912 3868913 3868914 3850426 3857511 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 65: ...l during the break in period than would oth erwise be normal Be sure to check the oil lev el frequently during the first 20 hours of operation since the oil consumption will be high until the piston rings are properly seat ed 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 pro...

Page 66: ...to ten minutes of operation run the engine at a fast idle above 1500 RPM 2 During the remaining first two hours of operation accelerate to bring the boat onto plane quickly bring the throttle back to maintain a planing atti tude During this period vary the engine speed fre quently by accelerating to approximately throt tle for two to three minutes then back to minimum cruising speed 3 After the en...

Page 67: ...gnition timing and idle RPM are within specifications 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 stern drive or inboard transmission power steering pump and trim pump Check propeller s and propeller fasteners Check condition of battery and ...

Page 68: ...eplace Tighten Once per day Cooling system leakage Emergency stop switch clip and lanyard Fuel system leakage 1 1 Always be constantly aware of the fuel system if you smell any fuel or notice any leaks shut off the engine immediately Thoroughly investigate the situation and make any necessary repairs before restarting the engine Oil engine crankcase Oil drive unit Safety equipment Shift system ope...

Page 69: ... Propeller and shaft Remote control shift cable damage Spark plugs 3 0 liter models 3 3 For all other engines Once every 3 years or 500 operating hours whichever comes first Spark plug wires boots deterioration 4 4 Replace as needed Once every 3 years or 500 operating hours whichever comes first Steering system cable operation 5 5 Lubricate once per season or every 50 operating hours whichever com...

Page 70: ...om measure from bottom of level to top of riser B and record measurement 3 Measure from bottom of the level to static water line A and record measurement 4 Subtract measurement B from measurement A and record result C Measurement C should not be less than 14 in 35 6 cm A B C 5 When the static water line does not meet these specifications contact your Volvo Penta dealer for information on high rise...

Page 71: ...s see Flame Arres tor on page 71 Make a thorough check of boat and engine for loose or missing nuts and screws Pump the bilge dry and air out engine com partment Federal state and or local regula tions prohibit the pumping of oil into any navigable waters Check all reservoir oil levels and fill as neces sary Check drive and transom shield anodes Clean or replace as necessary Off Season Storage Win...

Page 72: ...heck for Deteriorated hoses Burned hoses Loose clamps Evidence of water leaks Corrosion or blockage in the exhaust mani fold and riser s WARNING Replace damaged or defective components and securely tighten all clamps Any exhaust leak must be repaired before you operate your boat Exhaust leaks release fumes that can create hazardous conditions for operator and passengers Drive Unit Bellows WARNING ...

Page 73: ...NLY UNLEADED FUEL Use lead free gaso line with the following minimum or higher octane spec ification Inside the U S R M 2 AKI 87 Outside the U S RON 90 If fuels with 89 AKI pump posted 93 RON octane number or higher are used an increase in power can be expected with EFI models Mid grade and premium fuels contain injector clean ers and other additives that protect the fuel system and provide optimu...

Page 74: ...ial Inspect fuel tanks at least annually Replace fuel tanks if inspection indi cates leakage or corrosion Detonation Spark Knock Carbureted models Detonation or spark knock in a marine engine is not necessarily audible Overheating and continued running dieseling after ignition shut off are indications of detonation in a marine engine If you suspect detonation or spark knock and the en gine is tune...

Page 75: ...uretor GL The carburetor vaporizes fuel and mixes it with air in proper quantities to suit the varying needs of the en gine Except for changing the carburetor fuel filter screen the carburetor requires no periodic mainte nance or adjustment If operational problems occur see your Volvo Penta dealer Electronic Fuel Injection Gi GXi The electronic fuel injection EFI fuel metering sys tem delivers the...

Page 76: ...if necessary See your Volvo Penta dealer if further service is required CAUTION Do not run engine out of fuel or run the electric fuel pumps dry more than 20 sec onds Running the electric fuel pumps dry will damage the fuel pumps Fuel Filter All models have a fuel filter C in the fuel line before the fuel pump NOTE Volvo Penta EFI engines require a special marine filter with a 10 micron filtering ...

Page 77: ...cate the gasket C and inner seal D on new fuel filter 4 Screw on fuel filter and hand tighten following instructions on filter 5 Clean up any spilled fuel 6 Turn on the main battery switch or reconnect the battery 7 Run the bilge blower for at least five minutes to vent the engine compartment 8 Start the engine and check for leakage 9 Smell for fuel in the bilge DANGER If you can smell fuel turn t...

Page 78: ...ean up the bilge until fuel cannot be detected by smell Fuel Screen Cleaning 3 0 Liter Carb Engines 1 Turn off the engine 2 Disconnect the fuel line at the carburetor 3 Remove the fuel inlet nut gasket and screen B 4 Clean the screen with solvent then allow it to dry 5 Reinstall the screen gasket and fuel inlet nut 6 Tighten the fuel inlet nut securely 7 Reconnect the fuel line and tighten it secu...

Page 79: ... AWG 100 MWG cable 15 to 20 ft 4 6 to 6 1 m require a 3 0 AWG 120 MWG cable CAUTION Do not use aluminum core battery cables Failure to use battery cables of rec ommended gauge and material could result in poor starting and electrical component damage Batteries and Connections NOTE Whenever you replace your battery read and understand the information supplied with it before you begin installation B...

Page 80: ...re charge 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 battery and battery terminals may cause short circuits voltage drops and discharges especially in damp weather Clean battery terminals and leads to remove oxi dation Tighten cable terminals tightly Spray battery terminals and connections w...

Page 81: ... installation 1 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 MICA rating Refer to the section entitled Techni cal Data on page 113 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 supplie...

Page 82: ... Multiple Batteries and Selector Switch See your Volvo Penta dealer for multiple battery in stallation recommendations If your boat is equipped with multiple batteries and a selector switch the engine should be operated with the selector switch set to the ALL position This will provide charging system output to all batteries A battery isolator is recommended if batteries will be switched for indiv...

Page 83: ...ould ignite any fuel vapors in the engine compartment resulting in fire or explosion Do not operate engine if spark plug boots or high tension leads are torn or cracked This con dition could allow external sparks which could ignite any fuel vapors in the engine compart ment resulting in fire or explosion Checking and Changing Spark Plugs 1 Twist and pull only on the spark plug wire boot pulling on...

Page 84: ...ive blasting 7 Examine interior of plug in good light Remove any cleaning compound with compressed air If traces of carbon or oxide remain in plug finish the cleaning with a light blasting operation Clean firing surfaces of center and side electrodes with several strokes of a fine cut file 8 When spark plugs have been thoroughly cleaned carefully inspect them for cracks or other defects that may n...

Page 85: ...ower steering pump pulley This single belt replaces three separate belts alterna tor circulation pump and power steering belts The serpentine belt tension is adjusted automatically and requires no tension adjustments However at least once per year have your Volvo Penta dealer check the serpentine belt for wear An ideal time to have this check performed is when you have the gimbal bearing lubricate...

Page 86: ...arrow indicates position to be used for checking belt tension F Power Steering Pump Pulley V Belt Tension Belt tension is determined by belt deflection 1 With the engine stopped the belt should be tight enough so that it will deflect inch 6 mm when pressed with a finger or 75 10 pounds 333 6 44 5 N when using a belt tension gauge 2 If the belt is too tight excessive belt and bearing wear can occur...

Page 87: ...acket to the right 3 While maintaining pressure on the mounting bracket tighten the screw closest to the breaker bar position 5 then tighten the other screws 4 Recheck belt tension Alternator Belt With engine OFF check alternator belt deflection mid way between the circulating pump pulley and the al ternator pulley position A on image on previous page To increase belt tension 1 Loosen alternator m...

Page 88: ...w water is then routed to the exhaust manifolds where it is mixed with exhaust and dumped over board through the sterndrive exhaust port 3 The engine cooling fluid is recirculated between the engine and the heat exchanger by the engine circulation pump K 4 A thermostat inside the engine determines the amount of water to be taken in recirculated and discharged to control the engine s operating tem ...

Page 89: ...r the engine should not be run higher than idle or sea water may be drawn in with the fresh water 1 If the engine is running shut it down 2 Remove the blue plastic cap from the hose that is clamped to the starboard side of the engine It is marked with the running engine flush symbol 1 3 Connect a water hose from a fresh water source to the flush connector on the engine 2 4 Turn water on full and s...

Page 90: ... in the block Raw Water Cooled Engines 1 With the engine turned off locate and open the engine drain petcocks B located on both sides of the engine block CAUTION Be sure that all water is drained from the engine If no water drains when the petcocks are opened remove the petcocks and use a piece of wire to clear any obstruc tions from the drain hole Failure to drain all the water from the engine ma...

Page 91: ...Be sure the engine side of the sys tem has adequate antifreeze to protect it from the anticipated temperatures to be encoun tered Failure to maintain adequate antifreeze may result in engine damage during freezing temperatures 4 3 GL Draining Only When draining the 4 3 GL carbureted engine be sure to remove the intake manifold drain plug located be hind the alternator tensioning bracket to drain a...

Page 92: ...pump is located under the water line there is a risk of water penetration If you have a seacock installed close it now NOTE Always carry a spare impeller on board 1 Remove the hose clamps and hoses from pump 2 Remove the stationary bracket 1 3 Remove the four screws and remove the housing 2 4 Inspect the impeller 3 If there are cracks or other defects the impeller must be replaced Inspect the O ri...

Page 93: ...f needed add Volvo Penta Power Trim Tilt and Steering Fluid 3 Replace the fill cap and tighten securely Shaft Spline and Bearing Lubrication The primary shaft and bearings must be lubricated each year and whenever the drive unit is removed This procedure requires the removal of the drive unit therefore your Volvo Penta dealer should do it An ideal time to have this done is during the winterization...

Page 94: ...64 provide detailed information about oil filter type and service intervals When you add or change engine oil use Volvo Penta engine oils for gasoline engines Use the viscosity chart to select the SAE viscosity that matches the temperature range in which you expect to operate All models may use a mineral based oil However this requires an oil change at 100 hour intervals or earlier Switching betwe...

Page 95: ...pecial fitting is provided so that the oil does not have to be drained into the bilge 4 Withdraw oil with a suction pump NOTE You may purchase either a manual or an electric suction pump from any marine sup ply store or from your Volvo Penta dealer 5 Dispose of used oil according to any applicable federal state and local environmental regula tions 6 Replace the oil filter 7 Remove the oil fill cap...

Page 96: ... any moisture is present No metal flakes should appear in the oil NOTE On both the SX and DPS drives the drain plugs B and C are magnetized Any metal flakes in the drive will generally attach to the drain plugs 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 lubri cant to bring the oil level within the full r...

Page 97: ...e the drive in the run down position Remove the dipstick and check the oil level Reinstall the dipstick and tighten securely DPS only Re install the propellers You may refer to the section entitled Propeller Care on page 98 for instructions on replacing the propel ler 7 Check the oil level with the dipstick oil must appear on the full range of the dipstick Add oil if required through the dipstick ...

Page 98: ...you use a stainless steel propeller addi tional sacrificial anodes may be required to handle the added corrosion potential 2 Remove the two screws holding the anodes onto the gearcase and or the gimbal housing Set the screws aside you will use them again 3 Pull off the old anode 4 Insert new anode and secure with two screws 5 Tighten screws to these torque specifications 12 14 ft lb 16 19 Nm for t...

Page 99: ... metal hull the unit may be inadequate to protect the drive and transom shield 1 The green LED 1 indicates the unit is ade quately protected 2 If the green and red LEDs 2 are illuminated the drive is protected but the system is drawing maxi mum power between 3 to 150 mA to protect the drive unit Check the following conditions and solutions Water too severely contaminated or polluted Install additi...

Page 100: ... 4 If no LEDs are illuminated 4 the unit is not receiving power Check the following conditions Dead battery Check battery condition and charge as necessary Loose connection or corroded terminals on the electronic control unit or battery Clean and tighten the connectors Blown fuse Replace defective fuse The fuse 5 is located near the battery connectors Broken anode or reference sensor unit Re place...

Page 101: ...lication 1 Treat any bare aluminum with chromate conver sion coating 2 Rinse thoroughly with water The area must appear wetted or the surface is not clean and the paint will not adhere 3 While the surface is still wet from rinsing treat all bare aluminum with conversion solution Brush the chromate solution on the surface Add addi tional solution as necessary for 2 to 5 minutes to prevent it from d...

Page 102: ...aft 7 clean Inspect for fishing line remove if present Installing the SX Propeller CAUTION Failure to install all components could result in loss of propeller and damage to drive unit next time the boat is operated 1 Ignition switch must be OFF 2 Make sure the remote control is in NEUTRAL 3 Coat the full length of the propeller shaft and the inside of the propeller hub with Volvo Penta pro peller ...

Page 103: ...e to install all components could result in loss of the propeller and dam age 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 and the inside of the propeller hub with Volvo Penta pro peller shaft grease P N 828250 removal of the propeller will be difficult if this is not do...

Page 104: ...Vinyl butyl based antifouling paint is a recom mended alternative See your Volvo Penta dealer for an EPA approved an tifouling paint suitable for your area Engine Alignment Because of the special tools required a Volvo Penta dealer must do the engine alignment This should be done during off season storage preparations CAUTION Failure to periodically check en gine alignment may result in premature ...

Page 105: ...e following Circuit breakers alternator and related wiring Starter and related wiring Distributor distributor cap spark plugs high ten sion leads and related ignition parts Fuel pumps relays filter and related parts Rubber caps manifold hoses water and exhaust and attaching clamps Fuel injector O rings injector fuel line pressure relief valve and caps fuel reservoir vent hose and cover gasket high...

Page 106: ...Maintenance 102 VPA 7743722 English 10 2004 Notes 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 107: ...or cap 2 Coil and spark plug leads 3 Ignition timing 4 Automatic spark advance 5 Appropriate Ignition Troubleshooting Chart in the Electrical Igni tion Fuel Service Manual 6 EFI Models Refer to EFI Diagnostic Manual Fuel System EFI Models Refer to EFI Diagnostic Manual Carbureted Models Carburetor accelerator pump should squirt fuel into the Venturi when throttle is advanced If not check the 1 Fue...

Page 108: ...this record of information to iden tify potential causes of the malfunction Analyze this information and try to match it to similar situations you have experienced in the past Keep in mind the fundamental rules COMPRESSION Mixture inducted into cylinder and compressed SPARK Proper intensity at the proper time FUEL Proper mixture of air and fuel These are very old rules but necessary for the engine...

Page 109: ... from coil to spark plug Spark plugs for proper gap fouling burned electrodes or cracked dirty insulator See Electrical Ignition Fuel Service Manual Low battery voltage Fuel System Check Quantity and condition of fuel in boat tank Operation and flow capacity of boat anti siphon valve Fuel tank vent is unrestricted Fuel tank pick up screen is clean Correct diameter unrestricted boat fuel lines Fuel...

Page 110: ...djustment Carburetor accelerator pump Fuel system for leaks dirt or obstructions Engine timing and ignition system See Electrical Ignition Fuel Service Manual Hard Starting Hot Engine Ask these questions first Has Engine Always Done This Check Carburetor choke operation and adjustment See Electrical Ignition Fuel Service Manual Is This A New Condition Check Brand type or octane of fuel Spark plugs...

Page 111: ...gine compression Water or contaminants in fuel or water in cylinders See General Information on page 17 and the Electrical Ignition Fuel System Service Manual Engine Noises and Vibrations Valves Hydraulic Lifters Rapping only when starting oil too heavy for prevailing weather var nish on lifter oil needs to be changed Intermittent rapping leakage at lifter check ball Idle noise excessive leak down...

Page 112: ...nts or gimbal bearing Damaged internal drive components Worn bent or broken propeller hub or blades Loose worn or damaged engine coupler Engine Overheats Check Actual engine temperature by verifying with an accurate thermome ter Gauge operation and wiring circuit Sending unit operation and wiring circuit Supply pump circulating pump and belt s Water intake screens for blockage Thermostat Water sup...

Page 113: ...ck Primary and secondary ignition circuits Ignition switch Circuit breakers Wiring between engine and dash Main engine harness wiring See Electrical Ignition Fuel Service Manual Engine Stops Or Dies Out Due To Seizure Check Vertical drive for internal damage Oil pressure gauge and crankcase oil level Temperature gauge and cooling system operation Internal engine components as required Engine Won t...

Page 114: ... or foreign material caught on valve seat Oil pump relief valve plunger loose in cover Damaged filter bypass grommet Clogged oil pickup screen broken tube or housing Plugged crankshaft or blocked oil galleys Dirty or defective hydraulic lifters or clogged push rod passages Poor quality or incorrect viscosity or quantity of oil Incorrect hose routing on remote filter systems Water in crankcase oil ...

Page 115: ...o draw test battery and charg ing system Meter movement no matter how slight indicates draw from bat tery Disconnect main engine harness 10 Pin Connector Meter drops back to 0 indicates problem caused by boat sys tem continue to isolate each boat electrical accessory until problem is found Meter does not drop back to 0 indicates problem caused by engine electrical system continue to isolate each e...

Page 116: ...Troubleshooting 112 VPA 7743722 English 10 2004 Notes 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 117: ...rating Starter 12 volt 1 7kW output planetary reduction gear Ignition System Distributor Delco EST Ignition timing 2 ATDC special tool Volvo Penta PN 885163 required Spark plugs Volvo Penta PN 3851857 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 imp...

Page 118: ... Penta PN 3858997 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 PN 3587597 Oil Capacity Engine without filter 4 quarts 3 8 liters Engine with filter 4 5 quarts 4 3 liters Drive uni...

Page 119: ...ark 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 PN 3587597 GXi EF Closed cooling heat exchanger mounted on engine Closed Cooling System Thermostat 76 C 170 F Volvo Penta PN 3831426 Coolant Type Ethylene glycol Volvo Pent...

Page 120: ...uired Spark plugs Volvo Penta P N 3858996 2 units 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 PN 3587597 Oil Capacity Engine without filter 4 5 quarts 4 3 liters Engine with filt...

Page 121: ...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 PN 3587597 GXi EF Closed cooling heat exchanger mounted on engine Closed Cooling System Thermostat 76 C 170 F Volvo Penta PN 3831426 Coolant Type Ethylene glycol V...

Page 122: ...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 PN 3587597 Gi EF GXi FF Closed cooling heat exchanger mounted on engine Closed Cooling System Thermostat 76 C 170 F Volvo Penta PN 3831426 Coolant Type Et...

Page 123: ... See Workshop Manual for procedure Spark plugs Volvo Penta PN 3861326 2 units 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 PN 3587597 Gi EF GXi DF Closed cooling heat exchanger mo...

Page 124: ...Technical Data 120 VPA 7743722 English 10 2004 Notes 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 125: ...wtons N ACCELERATION feet sec2X 0 3048 meters sec2 m S2 inches sec2X 0 0254 meters sec2 m S2 ENERGY OR WORK foot poundsX 1 3558 joules j caloriesX 4 187 joules j BtuX 1055 joules j watt hoursX 3500 joules j kilowatt hrsX 3 600 megajoules MJ FUEL ECONOMY AND FUEL CONSUMPTION miles galX 0 42514 kilometers liter km l Note 235 2 mi gal liters 100 km 235 2 Iiters 100 km mi gal LIGHT footcandlesX 10 76 ...

Page 126: ...Metric Conversion Chart 122 VPA 7743722 English 10 2004 Notes 7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 127: ... Control Panel 33 Controls 29 Friction Brake 32 Side Mount 32 Single Lever 29 Top Mount 32 Cooling System 7 84 Core Value Environmental Care i Quality i Safety i Core Values i Cruising Speed 31 D Daily Checklist 8 Dealer 20 Hour Check 63 Decals 18 Defective Engine Lubricating System 110 Determining the Proper Trim 40 Detonation 70 Disengaging the Shift Function 29 Distributor Cap and Rotor 78 Do n...

Page 128: ...106 Hard Starting Hot Engine 106 High Altitude Operation 43 High Performance Boat Operation 11 High Performance Boating 11 Hot surfaces and Fluids 6 How to Shift and Control Speed 30 I ID Tags 18 Identification Numbers 18 19 Identification Plates 18 If the Engine Floods 36 Gi GXi Models 37 GL Models 36 Ignition Switch 21 Impact Protection 28 Impeller Checking Replacing 88 Installing the DP S Prope...

Page 129: ...SAE Viscosity Oils 61 Refueling 8 Remote Control Lever 33 Remote Control Unit 29 Removing the DP S Propeller 99 Removing the SX Propeller 98 Replacement Parts 20 59 101 Replacement Parts and Tools Checklist 10 Replacing Heat Exchanger Anodes 94 Replacing Sacrificial Anodes 94 Reverse Gear 31 S Sacrificial Anodes 94 Safety Emergency Stop Switch 22 Safety Checklists 10 Planning Your Trip 10 Safety E...

Page 130: ...ols 33 Trim Instruments 26 Trim Range 26 27 Trim Tilt Motor Protection 28 Trip Checklist 10 Troubleshooting 103 Troubleshooting System Isolation 103 113 Twin Unit Maneuvering 30 Twin Unit Steering 39 U Using the Gear Shift Release Button Method 1 38 Method 2 38 V VAS 17 V Belt Tension 83 Voltage 23 Voltmeter 21 Volvo Action Service 17 Volvo Penta Dealer Network 20 Volvo Penta on the Internet 20 W ...

Page 131: ... Dept 64620 SE 405 08 Göteborg Schweden Fax 46 31 545 772 Die Bestellung kann auch über das Internet erfolgen http www volvopenta com manual coupon Bitte beachten Sie dass dieses Angebot für die Dauer von 12 Monaten ab dem Lieferdatum des Bootes gilt danach bis zum Aufbrauchen des Lagerbestandes 42200 615001 155099900192 Oui merci Je souhaite recevoir un manuel d instructions gratuit en français N...

Page 132: ... Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Svezia Fax 46 31 545 772 L ordinazione può essere fatta anche su Internet http www volvopenta com manu al coupon Si ricorda che l offerta è valida per 12 mesi dalla data di consegna dell imbarcazione dopo il suddetto periodo l offerta resta valida solo in base alla disposizione della pubblicazione in oggetto 42200 615001 155099900192 Ja t...

Page 133: ...on Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sverige Fax 46 31 545 772 Bestillingen kan også ske på internet http www volvopenta com manual coupon Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato Derefter kun så længe lager haves 42200 615001 155099900192 Kyllä kiitos haluan suomenkielisen ohjekirjan veloituksetta Julkaisunumero Nimi Osoite Maa Postita tai faksaa ku...

Page 134: ...xemplares disponíveis 42200 615001 155099900192 Õ È fiËÂÎ Ì ÌÙflÙıðÔ ÙÔı Â ÂÈÒÈ flÔı ÒfiÛÁÚ ÛÙÁÌ ÎÈÍfi Î ÛÛ ÒflÚ Í ÏÈ Ò ÛÁ ÒÈËÏ Ú Í ÔÛÁÚ ºÌÔÏ ƒÈÂ ËıÌÛÁ Ò ı ÒÔÏfiÛÙÂ ıÙ ÙÔ ÍÔıð ÌÈ ÛÙÁÌ ð Ò Í Ù ÈÂ ËıÌÛÁ fi ÛÙÂflÎÙÂ ÙÔ ÏÂ ˆ Ó ÛÙÔÌ ð Ò Í Ù ÒÈËÏ ˆ Ó Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sweden Fax 46 31 545 772 ÃðÔÒÂflÙÂ ÂðflÛÁÚ Ì ÛÂÙÂ ÙÁÌ ð Ò ÂÎfl Û Ú Ï Û ÙÔı...

Page 135: ...7743722 Downloaded from www volvopenta com 13 05 2008 20 17 06 ...

Page 136: ...VPA 7743722 English 10 2004 7743722 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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