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Volvo Penta 3.0GLP-J Operator'S Manual Download Page 88

Electrical System

Battery Maintenance and
Replacement

22827

 DANGER!

Never allow an open flame or electric sparks near the
battery or batteries. Never smoke in proximity to the
batteries. The batteries give off hydrogen gas during
charging which, when mixed with air, can form an
explosive gas. This gas is easily ignited and highly
volatile.

 WARNING!

Battery electrolyte is a corrosive acid and should be
handled with care. If you spill or splash electrolyte on
any part of the body, immediately flush the exposed
area with liberal amounts of water and seek medical
attention as soon as possible.

NOTICE!

 Marine batteries should always be mounted

in approved marine battery boxes with covers. Always
make sure the battery is secured and the cover is
firmly shut.

NOTICE!

 Do not disconnect the batteries with the

engine running as sensitive electrical components
may be immediately damaged.

22840

NOTICE!

 Do not use wing nuts to secure battery

cables, even if they were supplied with the battery; use
a lock nut instead.

NOTICE!

 Some maintenance-free batteries have spe-

cial care instructions. Make sure to follow the battery
manufacturers instructions carefully.

NOTICE!

 When replacing your battery, read and

understand the information supplied with it before you
begin installation. Also, read the safety section of this
manual before carrying out any of these procedures.

The service life of your battery depends largely on how
it is maintained.

● Keep batteries and battery terminals dry and

clean. Oxidation or dirt on the battery and battery
terminals may cause short circuits, voltage drops,
and discharges (especially in damp weather).

● Tighten all battery connections. Loose battery

connections may cause damage to the engine’s
electrical system.

Maintenance

86

47700385 05-2009

Summary of Contents for 3.0GLP-J

Page 1: ...OPERATOR S MANUAL 3 0L 4 3L 5 0L 5 7L 8 1L SX A DPS A ...

Page 2: ...r gives ikke til tredje part Tämän ohjekirjan suomenkielisen version voi tilata veloituksetta 12 kuukauden sisällä toimituksesta internetistä postin kautta tai faksilla Katso tilauslomake kirjan lopusta AB Volvo Penta tallentaa kaikki tiedot sisäisesti eikä niitä luo vuteta kolmannelle osapuolelle Pode se encomendar uma versão gratuita deste manual de instruções em português até 12 meses após a en...

Page 3: ... 4 Introduction 12 Instruments and Controls 14 Optional 21 Starting 23 Operation 30 Engine Shutdown 45 In Case of Emergency 51 Troubleshooting 53 Maintenance Schedule 70 Maintenance 75 Storage 93 Technical Data 96 Alphabetical index 123 1 ...

Page 4: ...391 3869393 SX A DPS A 5 0L 5 0GL J 5 0GXi J 3869397 3869399 SX A DPS A 5 7L 5 7Gi300 J 5 7GXi J 3869403 3869407 SX A DPS A 8 1L 8 1Gi J 8 1GXi J 3869411 3869415 DPS A Fresh Water Cooled Engine Displacement Model Spec No Drive 5 0L 5 0GXi JF 3869400 DPS A OXI 5 7L 5 7Gi300 JF 5 7GXi JF 3869404 3869408 DPS A OXI 8 1L 8 1Gi JF 8 1GXi JF 3869412 3869416 DPS A OXI 2 47700385 05 2009 ...

Page 5: ...running costs and a reduction in service life Always observe recommended service intervals and make a habit of checking that the engine is operating normally every time you use it Contact an authorized Volvo Penta dealer if you cannot correct the fault yourself Remember that most chemicals used on boats are harmful to the environment if used incorrectly Volvo Penta recommends the use of biodegrada...

Page 6: ...ay result in equipment failure or damage This manual contains information you need to operate your boat engine and drive safely Check that you have the correct manual for your engine and drive This manual also contains a considerable amount of information concerning model identification preventive maintenance recommendations fuel and oil recommendations and other important points Please keep this ...

Page 7: ...ose nozzle firmly against the side of the deck filler plate or ground it in some other manner This action prevents static electricity buildup that could cause sparks and ignite fuel vapors DANGER Fuel leakage can contribute to a fire and or explosion Frequently inspect non metallic parts of the engine s fuel system and replace if excessive stiffness deterioration or fuel leakage is found DANGER To...

Page 8: ... s manuals and other information supplied with your new boat Learn to operate the engine controls and other equipment safely and correctly If this is your first boat or it is a boat type with which you are unfamiliar we recommend that you practice controlling the boat away from other vessels docks shallow areas and other obstacles Remember that the person driving a boat is legally required to know...

Page 9: ...olorless odorless and tasteless gas that weighs about the same as air It cannot be expected to rise or fall like some other gases because it will distribute itself throughout the space Do not rely on the sense of smell or sight of other gases to detect CO as it diffuses in the air much more rapidly than easily detectable vapors i e visible and aromatic vapors What Makes Carbon Monoxide Carbon mono...

Page 10: ...victim is not breath ing perform rescue breathing or approved car diopulmonary resuscitation CPR as appropri ate until medical help arrives Prompt action can make the difference between life and death Evacuate the area and move affected person s to a fresh air environment Observe the victim s Administer oxygen if available Investigate the source of CO and take correc tive action Marine CO Detectio...

Page 11: ...r around swim platform Do not swim in the vicinity of exhaust outlet s Since carbon monoxide production is greater when engines are cold versus when they are warm a boat operator should minimize the time spent on getting underway In order to minimize CO buildup do not warm up or run propulsion engine s for extended peri ods while the vessel is stationary A boat operator should be aware that carbon...

Page 12: ...in speeds and under certain operating conditions the low pressure area may form in other regions and permit carbon monoxide to enter the hull through openings that are not at the back of the boat Other factors during boat operation which may affect carbon monoxide concentration include Adding or removing canvas may raise or lower CO levels Image 51618 illustrates desired air flow through the boat ...

Page 13: ...l systems for altitude conditions may cause an increase in CO Reduced power resulting from increased altitude may require adjustments to propeller size Heavy seas or out of trim conditions tend to load engines resulting in reduced performance and increased CO pro duction Portable Generator Sets Do not use this equip ment on boats Gasoline powered portable gen erator sets produce CO These sets disc...

Page 14: ...ranty and registration form is on file at Volvo Penta Please refer to your warranty manual for additional informa tion Keep your owner s identification card with you at all times this will facilitate finding parts and providing service when you visit any Volvo Penta authorized dealer Volvo Action Service VAS Volvo Action Service VAS is a consumer breakdown service available 24 hours each day 365 d...

Page 15: ...and location of your nearest Volvo Penta dealer consult the telephone directory under Boat Dealers search the dealer locator on the internet or call 1 800 522 1959 Volvo Penta on the Internet Whether you re trying to replace a lost operator s man ual searching for updated service information about your engine looking for parts information or simply attempting to locate the nearest authorized Volvo...

Page 16: ...ral Hours run meter optional and separately installed displays the engine s operating time in hours and tenths of an hour 21179 2 Temperature Gauge Indicates engine temper ature Normal operating temperatures are listed in the section entitled Technical Data 3 Oil Pressure Gauge Indicates the engine oil pressure Normal operating oil pressures are listed in the section entitled Technical Data Lower ...

Page 17: ...es acceleration to planing Keeps the boat on plane at reduced throttle set tings Improves fuel economy Provides smoother and or drier ride in choppy water conditions Increases maximum speed If you do not wish to use this feature you may leave the drive unit trimmed to the position that works best for you NOTICE Avoid over trimming the drive system as this can have a severely adverse effect on the ...

Page 18: ... 4 In twin engine installations both drives can be oper ated simultaneously by pressing buttons 2 3 or but tons 5 6 Trimming out the Drive Press button 1 on the control panel or the trim button s on the control lever to raise the bow of the boat drive trimmed out The drives can be operated separately by pressing button 2 on the control panel for the port drive and button 3 for the starboard drive ...

Page 19: ...ant inlet is never trimmed out of the water Tilt Range Tilt range for either single or dual prop drive is any angle over 30 It is used to lift the drive to maximum height but not when the engine is running This range is used for trailing or putting the boat on the trailer Power trim has an automatic stop that cuts the power when its end limit has been reached The stop is reset automatically when a...

Page 20: ...an explanation of trim ranges please refer to Trim Ranges in the previous section Analog Instrument 51727 The analog trim instrument B shows the current posi tion of the drive This instrument has three ranges 1 Trim range 2 Beach range 3 Tilt range For an explanation of trim ranges please refer to Trim Ranges in the previous section Instruments and Controls 18 47700385 05 2009 ...

Page 21: ...ls other than those described below If Volvo Penta controls are not used ask your dealer for operating instructions for the remote control used in your boat since operation and function may differ from Volvo Penta remote controls 51260 b 1 Neutral Interlock Button 5 Starboard Trim Tilt Button 2 Trim Tilt Button 6 Port Engine Throttle Control Lever 3 Engine Throttle Control Lever 7 Starboard Engine...

Page 22: ...emote control mechanism 3 Place the control lever in reverse just beyond the reverse detent position and adjust the throttle brake screw to prevent throttle creep 4 Turn the tension screw B clockwise to increase drag and counter clockwise to decrease drag on the control arm 5 Reinstall the plastic cover and remote control lever Top Mount Remote Controls 51262 1 Make sure the engine is turned off b...

Page 23: ...otection system s control box has both red and green LED indicator lights A The lights will indicate the amount of protection that the unit is providing to protect the sterndrive and transom shield NOTICE The active corrosion protection system is designed to adequately protect one drive unit from gal vanic corrosion under normal operating conditions This system will not provide protection from str...

Page 24: ...roded terminals on the electronic unit or battery Clean and tighten connectors Copper bottom paint used and is in contact with the transom shield Remove paint and ensure there is a 25mm 1 in border between transom shield and bottom paint 22863 4 22826 4 If no LEDs are illuminated 4 the unit is not receiv ing power Check the following conditions Dead battery Check battery condition and charge as ne...

Page 25: ...weight to your boat the boat and engine exhaust will sit lower in the water This raises the water level in the exhaust If you add too much weight the water level will be high enough to allow water inges tion NOTICE Water ingestion damage from over loading is not covered by warranty Consider the static water line of your boat before add ing equipment such as generators appliances coolers and other ...

Page 26: ...he water and once it is full of water plug the top of the hose using your thumb or a clamp 5 Measure the vertical distance D from water line E in hose to the top of manifold B Measurement D should not be less than 14 in 35 6 cm 3 Bring plugged end of hose inside the hull C and hold next to and above the manifold B 6 If the static water line does not meet these specifications contact your Volvo Pen...

Page 27: ...lation in order to remove exhaust gases from the area Please see Carbon Monoxide in the section entitled Safety Information for additional details Do not start the engine out of the water unless you have connected a hose with running water to the engine flushing port see Engine Flush in the section entitled After Engine Shutdown for instructions Never use start spray or similar agents to start an ...

Page 28: ...to the ignition switch O Turn the key one step to the right I to switch on engine system voltage and instrumentation 6 Make sure that the fuel gauge is operating and that you have enough gasoline NOTICE 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 50404 7 Lower the drive unit to normal run posi...

Page 29: ...he ignition switch OFF 0 2 Disengage the drive mechanism by pressing the gear shift release button A 3 Depress the throttle lock and move the control lever to FULL THROTTLE B in order to activate the accelerator pump and prime the engine 4 Return the remote control handle to a fast idle position about 1000 RPMs 5 Turn the ignition switch to START II and hold it there until the engine starts but fo...

Page 30: ...EUTRAL detent position 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 NOTICE Never leave the key in the ON I position with the engine not running Never turn the key to START II when the engine is running Either situation could d...

Page 31: ...cause Fuel Injected Models To clear a flooded engine 1 Advance the remote control lever to the FULL THROTTLE B position NOTICE Be prepared to quickly move the control handle to IDLE once the engine starts This will avoid over speeding and possibly damaging the engine 2 Turn the ignition switch to START II If the engine does not start then try again In this throttle position with the engine speed b...

Page 32: ...d at the rear of the boat when the engine is running even if the drive is in neutral Personal injury could result from contact with propellers WARNING Check that nobody is in the water before engaging ahead or astern Never drive in or near areas where people could be in the water CAUTION Be sure you have read and understand everything in the section entitled Before Starting prior to continuing wit...

Page 33: ...ns include but are not limited to the following situa tions Low engine oil pressure Engine overheating Water in drive oil or low drive oil level OceanX only Water in drive bellows OceanX only Alarms sound in order to provide you with an audible warning that your engine or drive has a problem NOTICE Continuing to run the engine without correcting the cause of the problem may result in engine damage...

Page 34: ...at reduced throttle settings Improves fuel economy Provides smoother drier ride in choppy water Increases maximum speed The power trim is normally used before you accelerate onto plane after you reach the desired RPM 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 Trimmi...

Page 35: ...t s bow Trim Switch 22766 1 Trimming raising and lowering the drive can be per formed by using the trim switch located on the instru ment panel Center button Moves the drive trim out while raising the boat s bow The lower button moves the drive trim in while lowering the boat s bow The top button optional disconnects a catch so that the drive can be trimmed into the BEACH and TILT positions Press ...

Page 36: ...Watch the tachometer and speedometer readings and the ride action of the boat Operating in Bow up Position The bow up A position is normally used for cruising running with a choppy wave condition or running at full speed In a full bow up position the boat may tend to self steer You may have to compensate with the steer ing wheel to keep the boat in a straight ahead path In this position the boat s...

Page 37: ...waves the bow of the boat will plow into the water CAUTION The boat may tend to bow steer or spin about rapidly and possibly eject occupants The boat trim should be adjusted to provide balanced steering as soon as possible each time you get under way Some boat engine and propeller combinations may encounter boat instability and or high steering tor que when operated at or near the limits of the bo...

Page 38: ...ou are backing up You trailer your boat You launch your boat NOTICE 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 especially the transom shield assembly that contains steer ing system components Check the engine compart...

Page 39: ...of the gear shift release To disengage the shift from gear move the control lever to the neutral position press the gear shift release button then move the throttle control into or past idle Single Control Lever Operation 51260 1 Both the gear shift release and engine speed control are operated using the single lever 2 N Neutral position drive is disengaged and the engine runs at idle speed F Driv...

Page 40: ...ine systems before leaving the dock Move control handle s to the neutral detent posi tion N Check in front and behind boat for people or obstructions before shifting To go from forward to reverse or reverse to for ward always pause at neutral N and allow engine speed to return to idle After shifting is completed continue to move the control handle slowly in the desired direction to increase speed ...

Page 41: ...ot attempt to plane boat while operating on a single engine operating with a single engine at full throttle could cause engine or transmission damage Neutral Interlock Button 51266a The neutral interlock button 1 available on the side mount control only prevents accidentally moving the throttle out of neutral This button must be depressed to shift the throttle out of neutral To move the control le...

Page 42: ...e to wind and current This is normal and may be overcome by anticipating bow direction and cor recting with steering wheel A slightly higher throttle and trim setting may also lessen the tendency to wan der Changing weight distribution aft to forward can also affect slow speed steering Twin Unit Steering Twin engine boats may have only one engine with a fully operational power steering system That...

Page 43: ...ter may be forced back through the underwater exhaust outlet and cause serious engine damage 51311a WARNING Full lock when driving at high speed will make the boat turn sharply which entails a great risk of personal injury or that people aboard will fall over or be thrown overboard Warn everybody aboard before doing any emergency maneuvers Steering the Boat 51312 Put the control levers into forwar...

Page 44: ...t any speed above idle will allow water to be ingested into the engine causing serious engine damage Using this switch is simple and should not interfere with normal operation of the boat CAUTION Care must be taken to avoid accidentally pulling the lanyard during boat operation Unexpected loss of forward motion will occur which could cause occupants to be thrown forward In an emergency situation a...

Page 45: ...age to the engine and exhaust mani folds NOTICE Freeze damage to the engine package is not covered by your Volvo Penta limited warranty Upon completion of engine operation drain the engine as described below For raw water cooled engines drain the engine block and manifold For engines with closed cooling systems drain only the manifold Shallow Water Operation You may tilt the drive unit to reduce t...

Page 46: ...n operating at high speeds remember that other boaters may not realize the speed at which you are trav elling especially when you close in on another boat from astern or from ahead Always keep a good distance to allow for the unexpected Always be prepared for what other boaters may do unexpectedly High speed driving requires the driver to give a high degree of attention to boat operation and surro...

Page 47: ...the Engine 1 Move the remote control lever to NEUTRAL N 2 Let engine return to idle 3 Turn ignition key to OFF 0 NOTICE Do not stop the engine at speeds above idle or speed up the engine while turning off the ignition Do not stop the engine while in gear or while the boat is moving Engine damage could result from water being sucked back up through the exhaust ports NOTICE Always keep the drive til...

Page 48: ...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 start the engine 5 Let engine idle until engine temperature stabilizes at its normal operating range This will allow the thermostat to open and ensure the fresh water circula...

Page 49: ...e exterior with fresh water NOTICE Before moving the trailer tilt the drive as high as possible and secure it in place NOTICE Be very careful of high or low spots when backing up or crossing railroad tracks there is a possibility that the sterndrive may hit the ground 4 When you have reached your destination if the boat will be stored on the trailer the drive should be tilted down Engine Shutdown ...

Page 50: ...n securely 51534 a 3 Loosen the hose clamps and remove the hoses from the raw water pump 51604 4 Loosen the hose clamp on the large diameter hose and remove it from the circulation pump 5 Reinstall all hoses and secure all clamps in the same orientation as removed 4 3GL Draining Only The 4 3GL engine has the same draining procedure as all other raw water cooled engines except for the intake manifo...

Page 51: ...block and manifold If the engine is not level some water may remain trapped NOTICE When draining the starboard manifold take care to direct the drained water away from the starter to prevent water damage to the starter 2 After the water has completely drained reinstall the drain plugs and tighten securely 51534 3 Loosen the hose clamps and remove the hoses from the raw water pump 51604 4 Loosen th...

Page 52: ...ngine is not level some water may remain trapped NOTICE When draining the starboard manifold take care to direct the drained water away from the starter to prevent water damage to the starter 2 After the water has completely drained reinstall the drain plugs and tighten securely 51534 3 Loosen the hose clamps and remove the hoses from the raw water pump 4 Loosen the heat exchanger drain cap locate...

Page 53: ... Lift the boat ashore Check the drive oil level and qual ity If the oil is milky white water has entered the drive and it must be inspected by an authorized Volvo Penta workshop Replace the propeller if it is damaged To prevent galvanic corrosion any paint damage on the drive and propeller should be repaired before launching the boat again Tie Rod Twin Engines Only Check the tie rod connecting the...

Page 54: ...water and seek medical attention as soon as possible 1 Check that the auxiliary battery has the same voltage as the engine system voltage 2 Connect the red positive cable to the plus ter minal on the discharged battery and then to the plus terminal on the auxiliary battery 3 Connect the black start cable to the negative terminal on the auxiliary battery and to a place a little distance away from t...

Page 55: ...e boat loaded Did the trouble occur suddenly or did it become apparent gradually Whether servicing the boat s systems yourself or having your product serviced by a certified Volvo Penta dealer you will need this record of information to identify 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 f...

Page 56: ... and circuit breaker operation Call for assistance or see Volvo Penta authorized dealer Hard Starting Cold Engine Check Fuel lines for obstructions For debris inside fuel tank For clean fuel filter Water in fuel Fuel quality deterioration Fuel system for leaks dirt or obstructions Carburetor choke operation and adjustment Carburetor accelerator pump Ignition system Call for assistance or see Volvo...

Page 57: ...mproper tuning see dealer Cap and rotor for corrosion see Do It Yourself manual Proper octane fuel is used Call for assistance or see Volvo Penta authorized dealer Cooling System Check Supply pump Loose belts and or pulleys See section entitled Cooling System Call for assistance or see Volvo Penta authorized dealer Mountings Check Loose broken or worn engine mounts Loose lag screws holding mounts ...

Page 58: ...assistance or see Volvo Penta authorized dealer Engine Dies Out Refer to the section entitled Engine Protection Mode Loss of Fuel or Out of Fuel Check Fuel level in tank Water or debris in fuel Plugged fuel filter Fuel pickup tube and screen blockage Fuel tank vent blockage Air leak on suction side of fuel system Fuel leak on pressure side of fuel system DANGER Be extremely careful around fuel lea...

Page 59: ...l Call for assistance or see Volvo Penta authorized dealer Low Oil Pressure or Engine Knock Engine Components Check Oil quality dirt or water in oil Oil quantity Oil type and weight Call for assistance or see Volvo Penta authorized dealer Low Battery Voltage After Short Storage To Charge Check all battery and starter cable connections to ensure they are clean and tight Use a fully charged battery ...

Page 60: ...t 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 negative influence on boat performance is marine growth beneath the water line a problem that is often overlooked The propeller originally installed is frequently one that is...

Page 61: ...pressure engine overheat problem must be corrected before the engine will return to normal operation To reset the Engine Protection Mode after the problem is corrected reduce engine speed to idle allow the engine to cool and then continue with normal opera tion If you are unable to locate and resolve the problem you may be able to continue operating the engine at above idle speed keeping in mind t...

Page 62: ...ed by your warranty If safe to do so shut off the engine and allow oil to settle for five minutes Use the dipstick to check engine crankcase oil level If there is too much oil siphon out the excess until it reaches recommended levels If you are unable to remove oil from the engine make way at reduced speed only If there is not enough oil add more until it reaches recommended levels If you are unab...

Page 63: ...CE Ignoring an overheating situation can cause engine damage and or equipment failure which may not be covered by your warranty If the situation persists contact your Volvo Penta dealer for assistance Engine Overheating Carbureted NOTICE Carbureted engines are not protected against overheating If the engine overheats you must take action to protect your engine If your engine overheats the audible ...

Page 64: ...uality of the oil siphon off a small amount of oil from the drive Check to see if the oil has a milky or translucent white appearance If the oil has water in it it will appear milky If the alarm persists after checking the oil level and quality please contact your dealer for repairs as soon as possible Oil Sensor Reset Whenever the drive oil is replaced the drive oil sensor must be reset If your d...

Page 65: ...m will sound three beeps to acknowledge that the sen sor has been reset 8 Replace the cover and torque all screws to 13 17 ft lb 17 23 Nm Electric Fuel Pumps 22825 a EFI engines have two electric fuel pumps A high pressure pump A to supply the fuel injec tors A low pressure pump B to bring fuel from the boat tank to the engine Both pumps are protected by a single 20 amp fuse and relays The pumps w...

Page 66: ...ning or faulty fuses and relays use the spares provided 23672 3 0GLP J A Trim Down Relay F3 Not Used B Trim Up Relay F4 15 Amp Fuse Ignition C Starter Relay F5 Not Used D Not Used F6 Not Used E Ignition Relay F7 40 Amp Fuse Instrument Panel F1 Not Used F8 40 Amp Circuit Breaker Trim Pump F2 10 Amp Fuse Trim Control F9 20 Amp Fuse Starter 4 3GLP J 5 0GL J F A Trim Down Relay F3 7 5 Amp Fuse Fuel Pu...

Page 67: ... Relay F4 15 Amp Fuse Ignition C Starter Relay F5 5 Amp Fuse Vessel Switch D Fuel Pump Relay F6 20 Amp Fuse ECM E Ignition Relay F7 40 Amp Fuse Instrument Panel F1 15 Amp Fuse Diagnostic Connector F8 40 Amp Circuit Breaker Trim Pump F2 10 Amp Fuse Trim Control F9 20 Amp Fuse Starter Troubleshooting 47700385 05 2009 65 ...

Page 68: ...EUTRAL 3 Coat full length of prop shaft and inside of prop hub with Volvo Penta prop shaft grease removal of prop will be difficult if this is not done 4 Ensure thrust bushing 1 is on prop shaft with inner taper toward gearcase to match taper on prop shaft 5 Install the prop 2 onto the prop shaft aligning splines and push prop onto thrust bushing until splines are exposed 6 Install thrust washer 3...

Page 69: ...mponents 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 remote control is in FORWARD 3 Coat full length of prop shaft and inside of prop hub with Volvo Penta prop shaft grease removal of prop will be difficult if this is not done 4 Install front prop 1 5 Install front prop nut 2 and tighten it until th...

Page 70: ...icate all internal parts All electrical devices must also be dried and inspected for water damage 3 Frequently check engine compartment for gaso line fumes and excessive water accumulation In addition make sure that the water depth in the bilge is kept well below the flywheel housing NOTICE Delay in completing the above actions will result in extensive engine damage Trim Tilt Motor Protection If t...

Page 71: ...fluid level in the power steering pump reservoir The level must be between the Min and Max lines Check that all hose clamps on the power steering system are securely tightened Check all fittings to ensure they are securely tight ened Check all hoses and fittings for leaks pinches Troubleshooting 47700385 05 2009 69 ...

Page 72: ...uired to determine warranty coverage If the boat is sold these records should be transferred to the new owner Safety and Preventative Maintenance Checklists The following checklists provide the preventative maintenance program for the engine and power package suc cessful preventative maintenance is a key element of safe boat operation Preventative maintenance combined with regular completion of th...

Page 73: ...ower Steering Fluid Check level Remote Control and Shift System Check for proper operation 1 Fresh water cooled versions Owner s Checklist Check Each Month 1 Check Correct Fill Lube Adjust Tighten Clean Change Replace Batteries and Connections Batteries hold charge connections clean and tight Drive Unit Oil Exhaust Hoses and Bellows Check for damage leaks and loose clamps Bellows U joint and Exhau...

Page 74: ...these items to deter future problems If any items fail the checks the dealer should correct them as needed Scheduled maintenance and any corrective work performed are part of normal maintenance and as such are not part of warranty Exceptions may occur based on what the dealer finds during the service work Always insist that your dealer use genuine Volvo Penta parts oils and lubricants when servici...

Page 75: ...ck for Campaigns or Recalls Check serial number on Partner Network Serpentine Belt Wear tension PCV Valve 1 Check Oil and Filter 2 3 4 Change Fuel Pump and System Check for leaks Flame Arrestor Properly secured Fuel Filter Replace Exhaust Hoses and Bellows Check for damage leaks loose clamps Exhaust Manifolds Risers Pipes Check for cor rosion damage leaks Cooling System Check coolant level 5 check...

Page 76: ...imbal Bearing Check for wear corro sion Gear Oil Change Miscellaneous Batteries and Connections Batteries hold charge connections clean and tight Engine Alignment Check General Inspection All engine and drive hard ware clamps screws nuts etc Power Steering Check for proper operation check hoses and components for leaks Power Steering Fluid Check level Steering System Cable s Check for proper oper ...

Page 77: ...osions In your Volvo Penta product certain fuel and electrical system components have been designed to comply with U S Coast Guard and other regulations for explosion prevention Parts or components that comply with these regulations are designed so they will not emit fuel vapors or cause ignition of fuel vapors in the engine compart ment To prevent explosion or fire do not substitute automotive or...

Page 78: ...unning be undertaken by an authorized Volvo Penta workshop Starting the Engine After Service Reinstall all protective parts removed during service operations before starting the engine Make a point of familiarizing yourself with other risk factors such as rotating parts and hot surfaces exhaust manifold starter etc Check that no tools or other items have been left on the engine Fire and Explosion ...

Page 79: ...ids in supply lines and hoses when the engine has just been turned off and is still hot Hot oil can cause burns Avoid skin contact with hot oil Never start or operate the engine with the oil filler cap removed hot oil could spray out Cooling System CAUTION Avoid opening the filler cap for engine coolant system freshwater cooled engines when the engine is still hot Steam or hot coolant can spray ou...

Page 80: ... not be modified in any way except with accessories and service kits approved by Volvo Penta Only genuine Volvo Penta replacement parts may be used No modifications to the exhaust pipes and air supply ducts for the engine may be under taken The servicing of ignition timing and fuel injec tion systems must always be carried out by an authorized Volvo Penta workshop Seals may only be broken by autho...

Page 81: ... pulley D raw water pump pulley E and circulating pump pulley F Check the indicators located on the automatic ten sioner housing to determine the amount of tension loss When tick marks G and H coincide it s time to replace the serpentine belt As long as mark G is between marks H and I the belt has adequate tension on it Also check the serpentine belt for Regularly spaced cracks Regularly spaced mi...

Page 82: ...ets U S Military Specification 18001 H Some after market anodes may not meet mil specs Inspecting Heat Exchanger Anodes Engines with closed cooling systems have anodes located at the top of the heat exchanger This anode C resembles a bolt and may be removed and replaced using a 3 4 inch 19mm wrench When installing tighten the anode all the way by hand then turn an additional quarter turn using a w...

Page 83: ... spill from fuel pump or filter 5 Remove the fuel inlet nut gasket and ceramic screen B Discard ceramic screen and gasket 6 Install new screen new gasket and fuel inlet nut 7 Tighten the fuel inlet nut securely 8 Reconnect the fuel line and tighten it securely Torque to 80 in lb 9 Nm 9 Clean up any spilled fuel 10 If possible remove gasket ceramic screen con tainers and absorbant rags from the boa...

Page 84: ...repared to catch any excess fuel that may spill from fuel pump or filter 5 Using clean engine oil lightly lubricate the gasket C and inner seal D on the new fuel filter 6 Screw on fuel filter and hand tighten 7 Clean up any spilled fuel If possible remove the old fuel filter containers and absorbant rags from the boat Dispose of safely and according to local environmental reg ulations 8 Turn on th...

Page 85: ...d to catch any excess fuel that may spill from fuel pump or filter 5 Using clean engine oil lightly lubricate the gasket C and inner seal D on the new fuel filter 6 Screw on fuel filter and hand tighten 7 Clean up any spilled fuel If possible remove the old fuel filter containers and absorbant rags from the boat Dispose of safely and according to local environmental reg ulations 8 Turn on the main...

Page 86: ...emove long bolt 1 save for reuse 2 Place lifting eye 2 in a secure location you will need to reattach it later 3 Loosen and remove short bolt 3 save for reuse 4 Remove thermostat housing 4 5 Remove thermostat 5 O ring 6 and gasket 7 from intake manifold 8 Discard gasket and ther mostat Inspect O ring and if damaged replace 6 Clean intake manifold and thermostat housing surfaces where the gasket ma...

Page 87: ...seacock installed close it now to prevent any possible water intrusion NOTICE Always carry a spare impeller on board 1 Remove the hose clamps and hoses from pump 2 Loosen the four screws 1 and remove the housing 2 3 Inspect the impeller 3 If there are cracks signs of burning or melting on the edges or any other visible defects the impeller must be replaced Inspect the O ring 4 for nicks cuts and w...

Page 88: ...t the batteries with the engine running as sensitive electrical components may be immediately damaged 22840 NOTICE Do not use wing nuts to secure battery cables even if they were supplied with the battery use a lock nut instead NOTICE Some maintenance free batteries have spe cial care instructions Make sure to follow the battery manufacturers instructions carefully NOTICE When replacing your batte...

Page 89: ...enance Please see Maintenance Schedule for replacement frequency WARNING Ensure that plug wires are in good condition to avoid sparking Sparking could potentially cause a fire or explosion Please refer to your Do it Yourself manual for replace ment procedures 23172 e Maintenance 47700385 05 2009 87 ...

Page 90: ... It Yourself manual 3 Check O ring on dipstick for wear or nicks Replace if needed Tighten dipstick to 48 72 in lb 5 4 8 1 Nm During oil level check inspect oil for signs of water intrusion The oil should be amber in color Milky look ing oil indicates water mixed with the oil Also check for metal or other debris in oil If moisture or metal flakes appear in the drive unit oil take the boat to your ...

Page 91: ...d to the shift cable hose located inside the transom shield just behind the engine Once you have located the pitot tube hose remove the speedometer hose C from the plastic barb fitting B 2 Attach the hose from an air compressor to the barb fitting 3 Have someone assist you by placing a rag in front of the pitot tube at the leading edge of the lower unit 4 Blow air pressurized to no more than 116 P...

Page 92: ...m the drive anode is a good indication of the condition of the transom shield anode Inspect anodes see Maintenance Schedule for fre quency If an anode is 2 3 its original size 1 3 eroded replace it If additional electronic or electrical equipment is instal led each item should have an individual anode or grounding device and all grounding devices must be interconnected Follow equipment manufacture...

Page 93: ...er based paint on your boat bottom leave a 1 inch border between the paint and the transom shield Failure to follow this instruction will result in severe corrosion of the transom shield and drive system Propeller Propeller Care A damaged or unbalanced propeller will cause exces sive vibration and a loss of boat speed Under these conditions stop the engine and check the propeller for damage If the...

Page 94: ...y sit uations while in the water will be very difficult or impos sible Please refer to the section entitled Troubleshoot ing Propeller Replacement for additional information Steering Power Steering Reservoir Fluid Level Whenever you check the engine oil also check the steering reservoir fluid level The fluid level must be above the Min line and below the Max line If needed add Volvo Penta Power Tr...

Page 95: ...Your dealer will provide the proper servicing and maintenance to ensure that your equipment is treated and stored properly Short Term Storage Overnight or up to two months Flush engine with fresh water Raw Water Cooled Engines Only Drain raw water from manifolds and engine block See information on draining the engine in the section entitled Engine Shutdown Draining Raw Water Cooled Engines Closed ...

Page 96: ... information on draining the engine in the section entitled Engine Shutdown Draining Raw Water Cooled Engines Closed Cooing Engines Only Drain and replace engine coolant Drain raw water from manifolds See information on draining the engine in the section entitled Engine Shut down Draining Raw Water Side of Closed Cooling System Engines Store battery as recommended by manufac turer 1 After adding f...

Page 97: ... install battery and attach bat tery cables Open the fuel shut off valve and check fuel system for leaks Check the flame arrestor and clean if nec essary please see the Do it Yourself manual for additional information Pump the bilge dry and air out engine com partment Federal state and or local regu lations prohibit the pumping of oil into any navigable waters Check all oil and fluid levels and fi...

Page 98: ...Technical Data Engines Disclaimer Volvo Penta of the Americas Inc reserves the right to make changes in weight construction materials or specifications without notice or obli gation 96 47700385 05 2009 ...

Page 99: ...ation torque Delco EST 2 ATDC See Tune up and Color Code Decal on engine cover or Parts Catalog 0 050 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 160 F 71 C OIL FILTER Engine oil filter Volvo Penta spin on can OIL CAPACITY NOTICE Overfilling the oil can ...

Page 100: ...que Delco EST 1 BTDC See Tune up and Color Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C OIL FILTER Engine oil filter Volvo Penta replaceable paper element OIL CAPACITY NOTICE Overfilling the oil...

Page 101: ...T 10 BTDC Fixed See Tune up and Color Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C OIL FILTER Engine oil filter Volvo Penta replaceable paper element OIL CAPACITY NOTICE Overfilling the oil can ...

Page 102: ...r gauge required 10 BTDC See Tune up and Color Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine ...

Page 103: ... engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Volvo Penta rep...

Page 104: ... on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Volvo Penta ...

Page 105: ...n engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Volvo Penta re...

Page 106: ... for procedure See Tune up and Color Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 160 F 71 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene g...

Page 107: ...l for procedure See Tune up and Color Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 160 F 71 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene ...

Page 108: ...level is checked with a cold engine the oil level on the dipstick could be above the actual level If the oil level is checked directly after shutting the engine off the oil level on the dipstick will be low To get an accu rate oil level reading on the dipstick 1 Run the engine to normal operating temperature then shut it off and wait at least 5 minutes 2 Remove the dipstick and check the oil level...

Page 109: ...ous Maintain oil level between E add and D full on the dipstick If oil is added use an approved Volvo Penta oil for gasoline engines if unavailable use a high quality oil that meets the Engine Oil Specifications NOTICE Mineral oil is required for the first 150 hours or three years whichever occurs first Scheduled Oil Service NOTICE All oil used for oil changes or added between changes must meet th...

Page 110: ...leakage is found DANGER To prevent fire and explosion perform all service pro cedures with the engine turned OFF DANGER Failure to inspect your work may allow fuel leakage to go undetected This could become a fire or explosion hazard Gasoline Requirements Octane Use unleaded gasoline with the following minimum octane rating In the U S R M 2 AKI 87 Outside the U S RON 90 NOTICE Engine damage result...

Page 111: ...blended fuels How ever ethanol blended fuel can act as a solvent loos ening and washing old deposits or contaminants into the fuel system NOTICE Fuel system or engine damage caused by contamination from water foreign particles sludge or gums entering or forming in the fuel system is not cov ered by the warranty Volvo Penta gasoline engines are equipped with a water separating fuel filter see Engin...

Page 112: ...ount of fuel to the engine under all operating conditions The EFI system is controlled by a microprocessor and requires no periodic mainte nance or adjustment If operational problems occur see your Volvo Penta dealer Detonation Spark Knock Detonation or spark knock is continually monitored by the electronic fuel injection EFI system The EFI s computer ECM will automatically alter spark advance to ...

Page 113: ...ace the battery with one that has the same or better cold cranking amps and reserve capacity as the battery installed in your boat by the boat builder If you are unsure of the battery to be used consult your dealer NOTICE Failure to use a battery of recommended specifications could result in poor starting and electri cal component damage NOTICE Do not use deep cycle batteries to start the engine A...

Page 114: ...rvice GL 5 synthetic gearcase lubricant Sterndrive Oil Capacity All SX A Models 2 58 quarts 2 44 liters All DPS A Models 2 38 quarts 2 25 liters NOTICE If your drive is equipped with a Drive Spacer you will need to add more oil than the recommended amount We urge you to check the oil level with the dipstick whenever you are changing or topping up the oil Technical Data 112 47700385 05 2009 ...

Page 115: ...he exact locations of engine decals tend to vary also 22772 The engine decal is located on the engine cover 22774 The engine plate is typically located on the port side of the engine flywheel housing slightly below and aft of the exhaust manifold 3863274 The label depicting the serpentine belt configuration is typically mounted on a flat surface located on the front of the alternator automatic ten...

Page 116: ...ontrol Information sticker is located on the flat outside face port side of engine of the alternator support bracket 22775 The tune up and color code decal is located on the engine cover Technical Data 114 47700385 05 2009 ...

Page 117: ...ne Decal Product Designation A Specification No B Serial No C 22772 1 Engine Plate Product No A Type B Serial No C 22774 1 Transom Shield Plate Product No A Type B Ratio C Serial No D 22778 1 Drive Product No A Type B Ratio C Serial No D 22778 1 Transom Assembly Drive Unit Stickers Product Designation A Specification No B Serial No C 22780 1 The Transom Assembly Drive Unit Stickers shown above sho...

Page 118: ...ational Craft Propulsion Engines Declaration of Conformity for Recreational Craft Pro pulsion Engines with the sound and exhaust emission requirements of Directive 94 25 EC as amended by 2003 44 EC Technical Data 116 47700385 05 2009 ...

Page 119: ...Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex I B 4 Annex I C Noise Emissions Sound emission levels EN ISO 14509 2000 prA1 2004 Annex I C 1 Operator s manual IS...

Page 120: ...W EXVOL002 SDVOL009 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex I B 4 Annex I C Noise Emissions Sound emission levels EN ISO 14509 2000 prA1 2004 Annex I C 1 ...

Page 121: ... EXVOL003 SDVOL010 5 0 GXi F 3869400 201 kW EXVOL003 SDVOL010 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex I B 4 Annex I C Noise Emissions Sound emission level...

Page 122: ...39 kW EXVOL004 SDVOL012 5 7 GXi F 3869408 239 kW EXVOL004 SDVOL012 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex I B 4 Annex I C Noise Emissions Sound emission ...

Page 123: ...W EXVOL005 SDVOL013 8 1 GXi F 3869416 313 kW EXVOL005 SDVOL013 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex I B 4 Annex I C Noise Emissions Sound emission leve...

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Page 125: ...sion 68 Engine Troubleshooting Guides 53 Engine General 79 Engines 96 Flooded Engine 29 Friction Brake 20 Fuel Filter Replacement V6 V8 Carb Engines 82 Fuel Screen Replacement 3 0 Liter Carb Engines 81 Fuel System 81 108 Gauges 14 General Safety Information 4 General Warnings 108 High Altitude Operation 44 High Performance Boat Operation 44 Hour Meter 72 Hull Weight 58 Identification Numbers 113 1...

Page 126: ... Static Water Line 23 Static Water Line Test 24 Steering 69 92 Steering System Operation 40 Steering with Control Levers 41 Stop the Engine 45 Stop the Engine Before Service 76 Tie Rod Twin Engines Only 51 Trailering Your Boat 47 Trim Tilt Motor Protection 36 68 Twin Unit Maneuvering 39 Twin Unit Steering 40 Warranty Information 12 Washing the Engine 78 Water in Bellows 62 Water in Oil and Oil Lev...

Page 127: ...ddress and desired language http www volvopenta com manual coupon Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sweden Fax 46 31 545 772 Publication Reference 47700385 Name Address Country E mail English Svenska Deutsch Français Español Italiano Nederlands Dansk Soumi Português Ελληνικά Русско Türkçe ...

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Page 130: ...VPA 47700385 English 05 2009 47700385 ...

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