Volvo Penta 5.0 GL Manual Download

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VPA 7748089 English 09-2007

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Summary of Contents for 5.0 GL

Page 1: ...Workshop Manual Engine C 2 0 5 0 GL 5 7 Gi 5 0 5 7 GXi 5 0 5 7 OSi 5 7 OSXi ...

Page 2: ...ericas Inc All rights reserved This publication may not be copied photocopied reproduced or converted to any electronic or machine readable form in whole or in part without the express written consent from Volvo Penta of the Americas Inc ...

Page 3: ...VPA 7748089 English 09 2007 i Model Identification 1 General Information 3 Engine 5 0 5 7 Litre 29 Safety S1 ...

Page 4: ...ii VPA 7748089 English 09 2007 Notes ...

Page 5: ...nsom shield and drive unit will result in poor boat performance and risk damage to engine and drive because of incorrect drive gear ratio On 3 0L engines the model identification plate is lo cated on the side of the valve cover 4 3 5 0 and 5 7 Gi GXi OSi OSXi models 8 1 Gi GXi OSi models All GL models For all other engines the model identification plate or decal is located either on the port side ...

Page 6: ...s locat ed on top of the drive in front of the upper gear hous ing cover The SX A transom identification plate is located on the lower left of the outer transom plate The identification plate for the SX A DPS A stern drives is located on the rear of the upper gear just above the parting line between the upper and lower gear housing 50328 PROD NO TYPE SER NO P OD R NO YP T E O S R E N 50327 50478 5...

Page 7: ... pear throughout the text Since models are subject to change at any time some photos may not depict actual product Good Service Practice Service required for stern drives is generally one of three kinds Normal care and maintenance which includes putting a new stern drive into operation storing engines lubrication and care under special operating conditions such as salt water and cold weather Opera...

Page 8: ... use clean fresh fuel when testing engines Troubles can of ten be traced to the use of old or dirty fuel Service Policy It is a Volvo Penta policy to provide dealers with service knowledge so they can give professional service demanded by today s consum er The Volvo Penta Training Centers frequent mailing of Service Bulletins Letters and Promotions Special Tools and this Service Manual represent t...

Page 9: ...or deterioration of one or more parts or components In the normal operation of an en gine these changes can take place gradually at a number of points so that it is seldom advisable to attempt an improvement in perfor mance by correction of one or two items only Time will be saved and more lasting results will be obtained by following a definite and thor ough procedure of analysis and correction o...

Page 10: ...kes Test Conclusion The indicated compression pressures are considered normal if the lowest reading cylinder is within 75 of the highest Example If the highest pressure reading was 140 PSI 75 of 140 is 105 Therefore any cylinder reading less than 105 PSI indicates an im properly seated valve worn valve guides piston cylinder or worn or broken piston rings Any cylinder reading 105 PSI or greater is...

Page 11: ...or Ignition Coil High Tension Lead Ignition Switch Circuit Wiring and Connectors Fuel System Components Fuel Tank Pickup and Screen Fuel Tank Vent Anti Siphon Valve if equipped Fuel Octane and Quality Boat Fuel Lines and Valves External Engine Fuel Filter Fuel Pump s and Line Carburetor Fuel Filter or Screen Carburetor Adjustments Compression Pressure Limit in PSI Max Min Max Min Max Min Max Min 1...

Page 12: ...uum gauge while operating the engine over a range of engine speeds Test Results 1 A steady vacuum reading between 14 and 19in Hg 47 64 kPa at idle indicates an engine in good mechanical condition 2 A vacuum reading below 14 in Hg 47 kPa at idle indicates an engine that is not developing enough vacuum Further test ing for base mechanical problems is needed 3 Possible causes of low intake manifold v...

Page 13: ...approx 4 in Hg 13 kPa from highest level H Leaking Valve Drops 2 in Hg 6 kPa from highest reading I Burned or Warped Valve Evenly spaced down scale flicker approximately 5 in Hg 17 kPa J Worn Valve Oscillates Approximately 4 in Hg 13 kPa K Weak Valve Springs Violent oscillations as RPM increases 5 10 15 15 20 25 30 0 5 10 10 15 15 20 25 30 30 0 5 10 15 15 20 25 30 30 0 5 10 15 20 25 30 0 5 10 10 1...

Page 14: ... from the use of gasoline with octane 86 AKI 89 RON and lower is considered misuse of the engine and will void the engine warran ty Volvo Penta suggests the use of 89 AKI or higher fuels These fuels have additives that are beneficial to maximum engine performance and long life of service components To prevent gum formation and corrosion in the fuel system use a Marine Fuel Stabilizer in the gasoli...

Page 15: ...ours frequently check the oil level Some what higher oil consumption is normal until piston rings are seated The oil level should be maintained in the safe range between the Add and Full marks on the dipstick This range represents approximately 1 litre 1 quart If it is necessary to add or change the motor oil use a quality oil with API service category SJ NOTICE Do not fill above full mark Overfil...

Page 16: ...ns NOTICE Do not fill above full mark Overfilling results in high operating temperatures foaming air in oil loss of power low oil pressure and overall reduced engine life Oil Filter Canister type Replace the oil filter whenever the motor oil is changed This filter is a self contained screw on type To remove unscrew filter canister counterclockwise and discard When attaching a new filter be sure th...

Page 17: ...n II automatic transmission fluid can also be used Do not over fill the pump reservoir Steering System Lubrication Every 60 days grease the steering ram with Volvo Penta grease Power Trim Tilt Fluid Level At the beginning of each boating season check the fluid level in the reservoir as follows Level should be between the MIN and MAX marks on the reservoir If necessary add Power Trim Tilt Steering ...

Page 18: ...ec tric fuel pumps dry will cause fuel pump damage Step 1 Prepare a storage mixture In addition to stabilization of the fuel it is highly desirable to have the valves and cylinders coated with a light film of oil previously accom plished through fogging Today s fuel injection manifolds are de signed with a complex air channel design that will not allow the traditional fogging oils to be injected p...

Page 19: ...ubricant Drain and refill with fresh GL 5 Synthetic Gear Lubricant or Mobilube 1 SHC Fully Synthetic SAE 75W 90 meeting or exceeding MIL L 2105C or D API GL 4 or 5 gear lubricant Refer to Vertical Drive Service Manual Step 4 Fog Engine Warm up engine to ensure fuel conditioner is throughout fuel system Use 1 2 pint 0 24 liter of Fogging Oil 12 oz 355 ml spray can to fog engine Remove flame arreste...

Page 20: ...or leaks 5 Check the flame arrestor and clean if necessary Reinstall make sure all parts are in place and tighten nut securely 6 Make a thorough check of the boat and engine for loose or missing nuts and screws Pump the bilge dry and air out the engine compartment WARNING To prevent a possible explosion operate the blower as recommended by the boat manufacturer before starting engine If the boat i...

Page 21: ... planing attitude to avoid excessive engine load NOTICE DO NOT RUN ENGINE AT A CONSTANT RPM FOR PROLONGED PERIODS OF TIME DURING THE BREAK IN PERIOD Next Eight Hours During next eight hours continue to operate at approximately three fourths throttle or less minimum planing speed Occasionally re duce throttle to idle speed for a cooling period During this eight hours of operation it is permissible ...

Page 22: ...cruising at 3600 RPM or less saves fuel re duces noise and prolongs engine life When starting a cold engine always allow engine to warm up grad ually Never run engine at full throttle until engine is thoroughly warmed up Be sure to check oil level frequently during the first 50 hours of operation since oil consumption will be high until piston rings are properly seated Submerged Engine or Water In...

Page 23: ...s fully seated and secure Inspect cable anchor and cotter pin at shift linkage on stern drive for proper installation and free movement 8 Inspect exhaust system Tighten all hose clamps and check for leaks Verify all clamps on exhaust and u joint bellows are prop erly located and tightened 9 Check tension on drive belt 10 Check all engine mount screws stern drive mounting nuts and transom shield mo...

Page 24: ...ning with a noticeable force With Engine Stopped Remove PCV valve from its mounting and shake it A metallic click ing noise should be heard indicating that valve parts are free and not sticking If ventilation system passes these two tests it can be considered functionally OK and no further service is required If it fails either test replace PCV valve and repeat Engine Idling Test If system still d...

Page 25: ...ischarged or dead Battery 2 Loose or corroded connections 3 Cranking System Troubleshooting Chart in the Elec trical Ignition Fuel Service Manual Ignition System Must have good spark at spark plugs If not check the 1 Distributor Cap 2 Coil and spark plug leads 3 Ignition timing 4 Automatic spark advance 5 Appropriate Ignition Troubleshooting Chart in the Electrical Ignition Fuel Service Manual 6 E...

Page 26: ...lerances settings measurements etc as they are written in the service manual Leave your mind free to analyze the problem Following is a list of the troubleshooting guides which may be found on the pages indicated Engine Will Not Crank 22 Hard Starting Cold Engine 23 Hard Starting Hot Engine 23 Engine Runs Rough 23 Engine Noises and Vibrations 24 Engine Overheats Check 25 Engine Dies Out 25 Defecti...

Page 27: ...for signs of fuel or oil that would indi cate a fuel pump failure Fuel pump relay circuit breaker operation External fuel filter canister and carburetor filter Carburetor accelerator pump See Electrical Ignition Fuel System Service Manual Cylinder Compression Check Conduct test following procedure in this section and com pare readings to Compression Limit Chart Hard Starting Cold Engine Ask these ...

Page 28: ...ectrical Ignition Fuel System Service Manual Is This A New Condition Check 1 Brand type or octane of fuel 2 Spark plugs 3 Water in fuel 4 Condition of battery and cables 5 Starter motor for overheat damage Did Engine Refuse To Start After Being Run Check 1 Ignition system primary circuit 2 Ignition coil s ignition module 3 Engine timing 4 Carburetor choke operation and adjustment 5 See Electrical ...

Page 29: ...Noises and Vibrations Valves Hydraulic Lifters 1 Rapping only when starting oil too heavy for prevailing weather varnish on lifter oil needs to be changed 2 Intermittent rapping leakage at lifter check ball 3 Idle noise excessive leak down rate faulty check ball seat 4 Generally noisy excessive oil in crankcase stuck lifter plunger 5 Loud noise at operating temperature scored lifter plunger fast l...

Page 30: ...mp circulating pump and belt s 5 Water intake screens for blockage 6 Thermostat 7 Water supply hoses 8 Engine timing 9 Water leaks on pressure side of supply pump 10 Air leaks on suction side of supply pump including the transom shield and sterndrive 11 Engine compression Engine Dies Out Loss Of Or Out Of Fuel Check 1 Fuel gauge operation and wiring 2 Fuel level in tank 3 Water or debris in fuel 4...

Page 31: ...required Engine Won t Reach Operating RPM Check 1 Propeller pitch or diameter damaged blades slipping hub 2 Crankcase oil volume 3 Marine growth on hull and drive 4 Fuel type or octane 5 Wrong Sterndrive gear ratio 6 Operating at high altitude 7 Restricted carburetor air intake 8 Restricted exhaust outlets in engine transom bracket or drive 9 Poor cylinder compression 10 Carburetor size and type c...

Page 32: ...perature 3 Oil pressure gauge and warning horn sender operation and wir ing 4 Oil level too high or too low oil level should be within the Safe range on the dipstick Low Battery Voltage After Short Storage Engine Boat Components Check 1 All electrical accessories including ignition circuit off 2 Disconnect main battery negative cable from battery 3 Connect ammeter or voltmeter in series between ne...

Page 33: ...Train 53 Valve Lifters and Guides Clean and Inspect 56 Valve Lifter Installation 57 Valve Lifter Pushrod Guides 57 Valve Push Rod 57 Install Rocker Arm Assemblies 58 Valve Lash Adjustment 58 Valve Rocker Arm Cover Installation 59 Cylinder Head 59 Cylinder Head Disassemble and Recondition 61 Cylinder Head Clean and Inspect 62 Valve Spring Straightness 63 Valve Stems 64 Valve Guide Reaming and Seat ...

Page 34: ...6 Micrometer Method for Crankshaft Bearings 126 Recondition Engine Block 132 Engine Block Plug 132 Engine Block Clean and inspect 135 Cylinder Boring and Honing 136 Boring Procedure 137 Engine Specifications 5 0 Litre 138 Engine Specifications 5 7 Litre 142 Fastener Tightening Specifications 146 Sealants Adhesives and Lubricants 149 Tune Up Specifications 149 Special Tools 151 General Description ...

Page 35: ...riveshaft The extension driveshaft is driven by the distributor which is gear driven by the camshaft The oil is drawn from the oil pan through a pickup screen and tube Pressurized oil is delivered through internal passages to lubricate camshaft and crankshaft bearings and to pro vide valve lash control in the hydraulic valve lifters Oil is metered from the valve lifters through the valve push rods...

Page 36: ...moving the distrib utor accessory brackets etc cover the openings with tape to pre vent the entry of contaminants Methods used to clean the engine will depend on the means which are available Steam cleaning pressure washing or solvent clean ing are some of the acceptable methods Allow the engine to dry thoroughly before beginning any work It is important that the engine be as clean as possible to ...

Page 37: ...ining The Engine Raw Water Cooled Engines 1 With the engine turned off locate and open the engine drain petcocks located on both sides of the engine block NOTICE Probe the drains with a wire to ensure rust particles have not blocked the drain 3 8 4 9 5 0 0 ...

Page 38: ...e drains with a wire to ensure rust particles have not blocked the drain 3 Note the hose orientation on the raw water pump Loosen the hose clamps and remove the hoses from the raw water pump 4 Crank the engine briefly 1 or 2 crankshaft revolutions but do not start the engine to clear the water from the pump 5 Loosen the hose clamp on the large diameter hose and remove it from the circulation pump ...

Page 39: ...e engine turned off locate and loosen the lower drain cap from the heat exchanger 1 After water has completely drained retighten the lower drain cap of the heat exchanger to 18 30ft lb 25 41 Nm 2 Note the hose orientation on the raw water pump Loosen the hose clamps and remove the hoses from the raw water pump Crank the engine briefly 1 or 2 crankshaft revolutions but do not start the engine to cl...

Page 40: ...icles have not blocked the drain After water is completely drained reinstall drain plugs and tighten securely Engine Lubrication Full pressure lubrication through a full flow oil filter is supplied by a gear type 4 Oil is drawn up through the oil pump screen and passes through the pump to the oil filter The oil filter is a full flow paper 67757 ...

Page 41: ...water hose from manifold 3 Loosen upper exhaust hose clamps then remove high rise elbow 4 Remove manifold attaching screws then remove the manifold Inspection 1 Inspect for cracks 2 To pressure check manifold use a plate such as pictured and a new elbow gasket to seal water passage in manifold Be sure to apply sealer to gasket Install rubber drain caps to manifold and secure with clamps Attach a G...

Page 42: ...i fold Carefully follow the steps below to insure a good seal NOTICE Before proceeding place shop towels in the manifold openings to prevent debris from entering the engine When the cleaning process is done use a shop vacu um to remove debris from the manifold riser and en gine 3 Clean the gasket mounting surfaces on both the riser and the manifold 4 Use spray on gasket remover to remove ALL trace...

Page 43: ...ful not to scratch or cut the black coating on the riser gasket NOTICE Do not use any sealant on the riser gasket 8 Install riser on to exhaust manifold 9 Make sure gasket is properly placed 10 Install bolts and washers to secure riser 11 Install any parts secured under bolts 12 Torque riser bolts in a crossing pattern to 40 Nm 13 30 ft lb Make at least two passes to insure proper torque is reache...

Page 44: ... 4 and washer on solenoid termi nal Tighten to 19 28 N m 14 20 ft lb 5 Install solenoid extension nut cover 3 6 Connect battery cable 2 to solenoid extension nut 7 Install battery cable bolt 1 and washer Tighten to 19 28 N m 14 20 ft lb NOTICE DO NOT overtighten the battery cable bolt The starter solenoid will be damaged 8 Install start wire 7 on solenoid stud S 9 Install start wire nut 6 and wash...

Page 45: ... closed cooling system engines come filled with Ethylene Glycol coolant Follow all local regulations for the disposal of Ethylene Glycol anti freeze Disconnect 4 Disconnect hoses from thermostat housing 5 Disconnect Throttle cable a Remove cotter pin 1 and washer 2 and remove throttle cable from throttle lever b Loosen and remove anchor block bolt 3 and nut 4 c Release cable block 5 and trunnion 6...

Page 46: ...Models GL Models See Electric Fuel and Ignition Workshop Manual 1 Disconnect distributor high tension leads and ignition primary lead from distributor cap 2 Remove the distributor cap bolts and discard 3 Remove the distributor cap 4 Mark the position of the rotor on the housing 23322 ...

Page 47: ...nect and remove alternator 9 Remove Fuse box 10 Carburetor fuel line from carburetor and fuel pump or fuel lines from fuel rails To disconnect fuel lines from fuel rail see Quick Connect Fitting Service in EFI Diagnostic Workshop Man ual CAUTION Refer to Fuel Pressure Relief Procedures found in EFI Diagnostic Workshop Manual before servicing any part of the fuel system Failure to follow these proc...

Page 48: ...able anchor block assembly distributor clamp and temperature sending unit Transfer additional hardware as required Clean Old pieces of gasket or RTV from the gasket surfaces Excessive carbon build up in the intake passages of the intake manifold Scale and deposits from the coolant passages of the intake manifold Disassemble Intake Manifold Gi GXi OSi OSXi 12 Remove Flame arrestor and bracket 13 Re...

Page 49: ...0 5 7 Litre 15 Remove Thermostat housing bolts 16 Remove Thermostat housing and discard gasket 17 Remove MAT MAP sensor stud and remove sensor from mani fold 18 Remove four retaining studs and remove fuel rail assembly 23312 23313 23314 23315 ...

Page 50: ...d 21 Remove and discard upper intake manifold to lower intake manifold gasket 22 Remove impulse limiter Clean and Inspect Wear Safety Glasses 1 Clean the upper intake manifold in cleaning solvent 2 Dry with compressed air 3 Clean the lower intake manifold in cleaning solvent 4 Dry with compressed air 23316 23317 23318 23319 23320 ...

Page 51: ...ake manifold NOTICE If reusing the fasteners apply threadlock Volvo Penta P N 1161053 or equivalent to the threads of the fuel meter body bracket bolt 5 Install upper intake manifold bolts 6 Tighten the upper intake manifold bolts in two stages First pass 5 N m 44 in lb Final pass 9 N m 80 in lb 7 Inspect O rings on fuel injectors Replace any damaged cut or missing O rings 8 Install the fuel injec...

Page 52: ...t onto the cylinder head Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head NOTICE Care must be used to apply the correct amount of sealant onto the gaskets Applying excessive amounts of sealant may prohibit the intake manifold gaskets from sealing properly NOTICE The lower intake manifold must be installed and the fasteners tightened while ...

Page 53: ...shaft bearing bore alignment and cause damage to the crankshaft bearings 8 Tighten the intake manifold bolts a Tighten the bolts in sequence 1 8 on the first pass to 3 N m 27 lb in b Tighten the bolts in sequence 1 8 on the first pass to 12 N m 106 lb in c Tighten the bolts in sequence 1 8 on the first pass to 15 N m 11 lb ft 9 Connect fuel lines to fuel rail See Quick Connect Fitting Ser vice on ...

Page 54: ...cer clockwise until the alignment marks on the crankshaft balancer 1 are aligned with the tabs on the engine front cover 2 and the number 1 piston is at top dead center of the compression stroke 2 If not already removed remove and discard the distributor cap screws 3 Remove the distributor cap 4 Install NEW distributor gasket onto the distributor 1 2 23322 ...

Page 55: ...tributor gear with the paint mark on the distributor housing 6 Align the slotted tang in the oil pump driveshaft with the distribu tor driveshaft Rotate the oil pump driveshaft with a screwdriver if necessary 7 Align the flat 1 in the distributor housing toward the front of the engine 1 ...

Page 56: ... the distributor rotor segment with the number 8 pointer 1 that is cast into the dis tributor base NOTICE If the distributor rotor segment does not come within a few degrees of the number 8 pointer the gear mesh between the distributor and camshaft may be off a tooth or more Repeat the procedure again in order to achieve proper alignment 10 Install the distributor clamp bolt and Tighten the bolt t...

Page 57: ...s See the General Information section in Electrical Ignition Fuel Service Manual for correct firing order and spark plug wire routing 14 Install oil pressure sending unit Connect 15 All electrical connections Apply black neoprene dip or equiva lent on all exposed connections 16 Fuel lines to carburetor and fuel pump or throttle body and fuel pump vapor separator 17 Throttle cable 18 All water hose...

Page 58: ... flanges for bending or damage b Rubber grommets and parts for deterioration Installation 1 New gasket 2 Valve rocker arm cover 3 Valve rocker arm cover bolts Tighten 1 Valve rocker arm cover bolts to 106 in lb 12 N m Valve Train Removal NOTICE Store all reusable components in an exact order so they can be reassembled in the same wear pattern lo cation from which they were removed Mark the front e...

Page 59: ...007 55 Engine 5 0 5 7 Litre 2 Remove pushrods and keep in order with the valve lifters and rocker arms 3 Remove valve lifter retainer bolts and valve guide retainer 4 Remove the valve guides and valve lifters 51055 11508 11509 ...

Page 60: ...mbly 2 Clean the components with cleaning solvent 3 Dry the components with compressed air Inspect NOTICE Parts that are to be reused must be marked sorted and organized for assembly 4 Inspect the valve rocker arm components for the following Wear or scoring of the valve rocker arm 3 ball area Valve rocker arm 3 pushrod sockets and valve stem con tact surface The contact surfaces should be smooth ...

Page 61: ...TION Always wear safety glasses when using compressed air 3 Dry the components with compressed air 4 Inspect the valve lifter pushrod guides 1 for excessive wear cracks or damage 5 Inspect the valve lifter guide retainer for wear damage or stress cracking in the leg areas 2 and wear or damage in the bolt holes 3 6 Inspect the valve lifter for the following Broken or damaged clip 1 Worn pushrod soc...

Page 62: ...f reusing the valve lifters install the valve lifters in the original positions 2 Install the valve lifters Valve Lifter Pushrod Guides 3 Install the valve lifter pushrod guides 4 Tighten the valve lifter pushrod guide bolts to 25 N m 18 lb ft Valve Push Rod NOTICE Be sure to keep parts in order Parts must be rein stalled into the original location and position 1 Install the valve pushrods Seat th...

Page 63: ... into posi tion the engine is in the number 6 firing position If this hap pens turn the crankshaft clockwise one revolution in order to reach the number 1 firing position 4 With the engine in the number 1 cylinder firing position adjust the exhaust valves for cylinder numbers 1 3 4 and 8 and the intake valves for cylinder numbers 1 2 5 and 7 using the fol lowing process Turn the valve rocker arm n...

Page 64: ...e pushrod up and down between you thumb and forefinger until there is no more up and down movement of the pushrod When all the valve lash is removed then turn the valve rocker arm nut clockwise 1 additional turn 360 Valve Rocker Arm Cover Instal lation 1 Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover NOTICE Do not reuse the valve rocker arm cover gasket...

Page 65: ...7 61 Engine 5 0 5 7 Litre 1 Remove spark plugs 2 Remove cylinder head bolts NOTICE Place cylinder head on two wooden blocks to prevent damage 3 Remove cylinder heads 4 Remove and discard head gaskets 317307 317217 317227 317233 ...

Page 66: ...st the valve spring compressor Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys Fail ing to use care may cause personal injury NOTICE Mark sort an...

Page 67: ...ems and cylinder heads on a buffing wheel 2 Clean the following components in cleaning solvent Valve stem keys 1 Valve spring cap 2 Valve spring 3 Cylinder head 3 Dry the components with compressed air CAUTION Always wear safety glasses when using compressed air 4 Use the J 8089 to clean the carbon from the cylinder head com bustion chambers NOTICE Be careful not to scuff the combustion chambers 5...

Page 68: ... 152 4 mm 6 0 in area must be repaired or replaced A cylinder head exhaust manifold deck with warping in excess of 0 05 mm 0 002 in within a 152 4 mm 6 0 in area must be repaired or replaced A cylinder head intake manifold deck with warping in excess of 0 10 mm 0 004 in within a 152 4 mm 6 0 in area must be repaired or replaced Valve Spring Tension 1 Use the J 9666 in order to measure the valve sp...

Page 69: ...ng of the valve and will disturb the engine assembly smoothness a Clamp the J 8001 on the exhaust port side of the cylinder head b Position the dial indicator so that the movement of the valve stem from side to side crosswise to the cylinder head will cause a direct movement of the dial indicator stem The dial indicator stem must contract the side of the valve stem just above the valve guide c Dro...

Page 70: ... Grinding Measuring Tools Required J 5830 02 Valve Guide Reamer Set J 8001 Dial Indicator Set 1 Measure the valve stem to guide clearance See Cylinder Head Clean and Inspect on page 63 2 Improper valve stem 1 to valve guide 2 clearance may cause excessive oil consumption J 8001 2 1 ...

Page 71: ...intake valve in order to measure the valve stem to guide clearance the valve stem to guide clearance is not within specifications 3 Use the J 5830 3 in order to ream the exhaust valve guide in order to achieve the correct valve stem to guide clearance 4 Always recondition the exhaust valve seat after reaming the exhaust valve guide bores and installing new exhaust valves Inspect 5 Inspect the valv...

Page 72: ... valve guide bores are free from carbon or dirt in order to ensure the proper centering of the pilot in the valve guide The valve seats should be concentric to within 0 05 mm 0 002 in total indicator reading Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the valve head and the valve stem Replace the valve if the valve stem is excessively worn o...

Page 73: ...5 Reamer 0 0762 mm 0 003 in J 6036 Reamer 0 0332 mm 0 013 in J 6880 Rocker Arm Stud Installer 1 Ream the hole to the proper size for the replacement oversize valve rocker arm ball stud Use J 5715 for 0 0762 mm 0 003 in oversize valve rocker arm ball studs or J 6036 for 0 03302 mm 0 013 in oversize valve rocker arm ball studs 2 Apply lubricant GM P N 1052271 or equivalent to the lower end press fit...

Page 74: ... 1 molded into the top of the seal The exhaust valve oil stem seal material is brown in color 2 with a white stripe 3 painted onto the outside diameter of the seal or the material may be red in color 2 with no paint stripe The intake valve oil seal is black in color Install Oil Seal 1 Assemble the valve into the proper valve guide 2 Select the proper valve stem oil seal for the specific valve guid...

Page 75: ... the valve guide Install Valve Spring 7 Install the valve spring 3 8 Install the valve spring cap 2 onto the valve spring 3 and over the valve stem CAUTION Wear Safety Glasses Compressed valve springs have high tension against the valve spring compressor Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor wi...

Page 76: ...upper groove of the valve stem c Tap the end of the valve stem with a plastic faced in order to seat the valve stem keys if necessary Installation 1 Clean the cylinder head gasket surfaces on the engine block 2 Inspect the dowel pins cylinder head locators for proper instal lation 3 Clean the cylinder head gasket surfaces on the cylinder heads NOTICE Do not use any sealer on the cylinder head gask...

Page 77: ...d bolts in sequence in two steps 1 First step 30 N m 22 ft lb 2 Final step use special tool J 36660 and tighten as follows a Tighten the long bolts 1 2 5 6 9 10 and 13 on the final step sequence to 75 degrees b Tighten the middle length bolts 14 and 17 on the final step sequence to 65 degrees c Tighten the short length bolts 3 4 7 8 11 12 15 and 16 on the final step sequence to 55 degrees 3 Instal...

Page 78: ...il from engine See Draining The Engine on page 33 2 Remove engine from boat See Removal and Installation Work shop Manual Removal 3 Disconnect and remove the dipstick tube Discard the O rings 1 and seals 2 4 Remove the oil pan bolts and nuts 5 Remove the oil pan 1 1 2 2 182850 182851 ...

Page 79: ...pressed air 3 Inspect the oil Gouges or damage to the oil pan sealing surfaces 1 The oil pan drain plug hole for damaged threads Damaged oil pan drain plug threads Damage to the oil pan reinforcements 2 Damage to the oil pan baffle Dents or damage to the exterior of the oil pan An oil pan that is dented may interfere with the proper position of the oil pump screen or may not distribute oil properl...

Page 80: ...p 3 the oil pump driveshaft 5 and the oil pump driveshaft retainer 4 4 Separate the oil pump 3 the oil pump driveshaft 5 and the oil pump driveshaft retainer 4 NOTICE Always install a NEW oil pump driveshaft retainer dur ing assembly 5 Discard the oil pump driveshaft retainer 6 Inspect the pins oil pump locator for damage and replace if required 11438 5 9 6 9 mm 0 24 0 27 ...

Page 81: ...the oil pump driveshaft and retainer 2 Remove oil pump screen if necessary The oil pump screen has a press fit into the oil pump cover DO NOT remove the oil pump screen from the pipe The pipe and oil pump screen are serviced as a unit 3 Remove the oil pump cover bolts 5274 5275 5276 ...

Page 82: ...move the oil pressure relief spring 2 9 Remove the oil pump pressure relief valve 3 Oil Pump Clean and Inspect 1 Clean the oil pump components in cleaning solvent 2 Dry the components with compressed air CAUTION Always wear safety glasses when using compressed air 3 Inspect the oil pump for the following conditions Scoring on the top of the gears 1 Damaged gears 2 for the following Chipping Gallin...

Page 83: ...ply clean engine oil GM P N 12345610 or equivalent to the oil pump pressure relief valve oil pump pressure relief valve spring and oil pump body CAUTION Wear safety glasses NOTICE Replace the oil pump pressure relief valve spring when you reuse the oil pump 2 Install the following items a The oil pump pressure relief valve b The oil pump pressure relief valve spring c The oil pump pressure relief ...

Page 84: ... screen must have a good press fit into the oil pump body c Mount the oil pump in a soft jawed vise d Apply sealant 1141570 or equivalent to the end of the oil pump screen pipe e Use the J 21882 and a soft faced hammer in order to tap the oil pump screen into the pump body 9 The oil pump screen must align parallel with the bottom of the oil pan when the oil pan is installed Oil Pump Pump Screen an...

Page 85: ... onto the pins 4 Install the crankshaft oil deflector 2 and the nuts 6 5 Install the bolt 1 attaching the oil pump to the rear crankshaft bearing cap Tighten Tighten the oil pump bolt on the first pass to 20 N m 15 lb ft Tighten the oil pump bolt on the final pass to 65 degrees using the J 36660 Tighten the crankshaft oil deflector nuts to 40 N m 30 lb ft Oil Pan Installation 1 Install the oil pan...

Page 86: ...in wide and 25 mm 1 0 in long bead of adhesive Volvo Penta P N 1161277 or equivalent to both the right and left sides of the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces NOTICE Always install a NEW oil pan gasket The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch 5 Install the NEW oi...

Page 87: ...et into the grooves of the engine front cover and crankshaft rear oil seal housing 7 Slide the oil pan back against a suitable straight edge 8 Using new seals and O rings install the dipstick tube Tighten bolt to 25 N m 18 ft lb NOTICE Always use new seals and O rings when the dipstick is removed 182851 1 1 2 2 182850 ...

Page 88: ...p pulley NOTICE It is not necessary to remove the belt from the rest of the other pulleys unless the belt is worn or deteriorat ed 2 Remove the bolts and the water pump pulley using the J41240 or suitable substitute 3 Remove the water pump bolts 4 Remove the water pump 5 Remove and discard the water pump gaskets Inspection The circulation pump is not a serviceable unit Replace the circula tion pum...

Page 89: ...rom the face of the mounting ports 3 Install the water pump and the NEW water pump gaskets 4 Install the water pump bolts and tighten to 45 N m 33 lb ft 5 Install the fan and water pump pulley and bolts using the J41240 or suitable substitute 6 Tighten the and water pump pulley bolts to 25 N m 18 lb ft 7 Release the belt tensioner and reinstall the serpentine belt NOTICE Be sure the belt is aligne...

Page 90: ...089 English 09 2007 GL Remove 1 Loosen power steering pump nut 2 Loosen power steering pump bolt 3 Loosen power steering pump pivot nut 4 Pull up on power steering pump belt to loosen belt tension and remove the belt 22916 22915 22919 ...

Page 91: ...on alternator belt to loosen the alternator and remove the belt Tools Required J 41240 Fan Clutch Remover and Installer 8 Remove the bolts and the fan and water pump pulley using the J41240 9 Remove the water pump bolts 10 Remove the water pump 11 Remove the water pump gaskets 12 Discard the water pump gaskets 22914 22918 J41240 ...

Page 92: ...d water pump pulley bolts to 25 N m 18 lb ft Tools Required 5 Install Alternator belt NOTICE Do not substitute automotive belts Belts used for the alternator circulating pump and power steering pump are heavy duty 6 Tighten alternator belt to 33 6 2 7 N 75 10 lb or 6 4 mm in deflection with light pressure on belt Check belt tension midway between the water pump pulley and the alternator pul ley 2 ...

Page 93: ...748089 English 09 2007 89 Engine 5 0 5 7 Litre Crankshaft Balancer Removal 1 Disconnect hoses from raw water pump 2 Remove raw water pump retaining bolts and remove the pump 3 Remove water pump stay bracket ...

Page 94: ... following Loose or improperly installed front groove pin 1 crankshaft balancer A properly installed front groove pin should be installed until flush or below flush with the face of the crank shaft balancer Important A crankshaft front oil sealing surface with excessive scor ing grooves rust or other damage must be replaced Worn grooved or damaged crankshaft front oil sealing sur face 2 Minor impe...

Page 95: ...l the crankshaft balancer onto the end of the crankshaft 4 Use the J 23523 F in order to press the crankshaft balancer onto the crankshaft a Install the J 23523 F plate and bolts onto the front of the crankshaft balancer Tighten the J23523 F plate bolts to 25 N m 18 lb ft b Install the J 23523 F screw into the end for the crankshaft c Install the J 23523 F bearing the washer and the nut onto the J...

Page 96: ... water hoses in the correct orientation and tighten clamps NOTICE Crossing the raw water hoses will damage the water pump impeller and engine Engine Front Cover Remove engine See Removal and Installation Workshop Manual Remove engine circulation pump See Water Pump on page 84 Remove crankshaft balancer and engine raw water pump See Crankshaft Balancer on page 89 Remove oil pan See Oil Pan and OIl ...

Page 97: ...ankshaft position sensor 3 Remove and discard the crankshaft position sensor seal O ring 4 Remove engine front cover bolts and front cover NOTICE The engine front cover is made of composite material and has an intergral gasket Once the front cover is re moved it must be discarded and a new front cover must be used 69010 ...

Page 98: ...t position sensor bore A crankshaft posi tion sensor that is not completely seated will cock in the engine front cover and may result in erratic engine operation 3 Lubricate the NEW crankshaft position sensor seal O ring with clean engine oil 4 Install the NEW crankshaft position sensor seal O ring onto the crankshaft position sensor 5 Install the crankshaft position sensor until fully seated into...

Page 99: ... sprocket 1 counterclockwise until all slack is removed from the camshaft timing chain 2 b Measure the free play on the slack side 3 of the camshaft timing chain If the camshaft timing chain can be moved side to side in excess of 11 mm 0 43 in replacement of the camshaft timing chain and the sprockets is recommended during assembly 4 Remove the camshaft sprocket bolts 5 Remove the camshaft sprocke...

Page 100: ...t using the J 5825 A 7 Remove the crankshaft balancer key Inspection 1 Clean the components with cleaning solvent 2 Dry the components with compressed air CAUTION Always wear safety glasses when using compressed air 3 Inspect the camshaft timing chain for binding or wear 11506 182847 ...

Page 101: ... edge of the teeth Worn valleys between the sprocket teeth 5 Inspect the crankshaft balancer key 1 the keyway 2 and the threaded hole 3 for damage 6 Repair or replace the crankshaft as necessary Installation Tools Required J 5590 Installer 1 Install the crankshaft balancer key into the crankshaft keyway The crankshaft balancer key should be parallel to the crank shaft or with a slight incline 1 2 ...

Page 102: ...until the crankshaft sprocket is at the 12 o clock position 5 Install the camshaft sprocket and the camshaft timing chain 6 Install the camshaft sprocket bolts and tighten to 25 N m 18 lb ft NOTICE Do not use a hammer to install the camshaft sprocket onto the camshaft To do so may dislodge the expan sion cup plug camshaft rear bearing hole 7 Install the camshaft sprocket with the alignment mark at...

Page 103: ... on page 94 2 Remove intake manifold Intake Manifold on page 41 3 Remove valve lifters Valve Train on page 54 4 Remove the camshaft retainer bolts and retainer NOTICE All camshaft journals are the same diameter so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings 5 Remove the engine camshaft a Install the three 5 16 18 x 4 0 inch bolts into the engin...

Page 104: ...engine camshaft for the following Worn scored or damaged bearing journals 1 Worn engine camshaft lobes 2 Damaged bolt hole threads 3 Damaged camshaft sprocket locator pin 4 7 Measure the engine camshaft journals with a micrometer If the camshaft journals are more than 0 025 mm 0 0010 in out of round then replace the engine camshaft 8 Measure for a bent engine camshaft or excessive engine cam shaft...

Page 105: ...to avoid damage to the camshaft bearings 3 Use the bolts as a handle in order to install the engine cam shaft 4 Remove the 3 bolts from the front of the engine camshaft 5 Install the timing chain and sprockets See Timing Chain and Sprocket on page 94 6 Install the valve lifters Valve Train on page 54 7 Install the intake manifold See Intake Manifold on page 41 Camshaft Bearings Remove Tools Requir...

Page 106: ... f Remove the camshaft inner bearing 2 from the J 33049 expander assembly g Insert the J 33049 expander assembly into the camshaft inner bearing 3 h Tighten the J 33049 expander assembly nut until snug i Push the J 33049 guide cone into the camshaft front bear ing in order to align the J 33049 j Drive the camshaft inner bearing 3 from the camshaft inner bearing bore 3 k Loosen the J 33049 expander...

Page 107: ...re 5 j Loosen the J 33049 expander assembly nut k Remove the camshaft outer bearing 5 from the J 33049 expander assembly 7 Remove the J 33049 from the engine block 8 Discard the camshaft bearings Installation Tools Required J 33049 Camshaft Bearing Service Kit NOTICE Always install the camshaft outer bearings 1 and 5 first The camshaft outer bearings serve as a guide for the J 33049 and help cente...

Page 108: ...ander assembly g Install the NEW camshaft outer bearing 1 onto the J33049 expander assembly h Tighten the J 33049 expander assembly nut until snug i Align the camshaft outer bearing 1 lubrication hole with the oil gallery hole in the camshaft outer bearing bore 1 at the front of the engine block j Drive the camshaft outer bearing 1 into the camshaft outer bearing bore 1 at the front of the engine ...

Page 109: ...049 expander assembly is positioned between the camshaft inner bearing bore 2 and the camshaft outer bearing bore 1 o Install the NEW camshaft inner bearing 2 onto the J33049 expander assembly p Tighten the J 33049 expander assembly nut until snug q Align the camshaft inner bearing 2 lubrication hole with the oil gallery hole in the camshaft inner bearing bore 2 of the engine block r Push the J 33...

Page 110: ...e all of the cylinder ring ridge d Turn the crankshaft so the piston is at the top of the stroke e Remove the cloth f Remove the cutting debris NOTICE Place match marks or numbers on the connecting rods and the connecting rod caps 5 Remove the connecting rod nuts 6 Remove the connecting rod cap 7 Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the pisto...

Page 111: ... rod bearings a Keep the connecting rod bearings with the original connect ing rod and connecting rod cap b Wipe the oil from the connecting rod bearings c Wipe the oil from the crankpin Piston and Connecting Rod Disassemble Tools Required J 24086 C Piston Pin Remover Installer CAUTION Wear safety glasses 1 Remove the piston rings from the pistons 204801 ...

Page 112: ... wire will become em bedded in the piston and damage the cylinder and pis ton Blasting techniques can be employed to remove hard carbon depos its if suitable equipment is available Suitable types of grit for dry blasting are plastic pellets and processed natural materials such as wheat grains and crushed fruit pits or shells Air pressure must be adjusted to the lowest setting that will produce the...

Page 113: ...of the piston ring into the piston ring groove e Roll the piston ring completely around the piston If binding is caused by a distorted piston ring groove MINOR imperfections may be removed with a fine file If binding is caused by a distorted piston ring replace the pis ton ring 7 Measure the piston ring side clearance with a feeler gauge 8 If the side clearance is too small try another piston ring...

Page 114: ...ameter Engine Specifications 5 0 Litre on page 139 14 Measure the piston with a micrometer at a right angle to the pis ton pin bore measure the piston at 11 mm 0 433 in from the bottom of the skirt Engine Specifications 5 0 Litre on page 139 15 If the piston is not within specifications replace the piston and pin as an assembly 16 Inspect the connecting rod for an out of round bearing bore Engine ...

Page 115: ...r to measure the end gap c Select another size ring set if the end gap exceeds specifi cations Engine Specifications 5 0 Litre on page 139 Piston Selection Tools Required J 8087 Cylinder Bore Gauge NOTICE Measurements of all components should be taken with the components at normal room temperature For proper piston fit the engine block cylinder bores should not have excessive wear or taper A used ...

Page 116: ...n Remover Installer CAUTION Avoid contact with HOT components Wear safety glasses and protective gloves to avoid personal injury NOTICE Applying excessive heat to the connecting rod may damage or distort the rod Rod temperature SHOULD NEVER exceed 315 C 600 F At this temperature the end of the connecting rod will turn a straw color upon visual inspection NOTICE After the J 24086 C installer hub bo...

Page 117: ...install the piston rings The rings may be damaged if expanded more than necessary 2 Install the piston rings onto the piston a Install the oil control piston ring spacer b Install the lower oil control piston ring c Install the upper oil control piston ring d Install the lower compression piston ring The mark on the side of the piston ring should face the top of the piston e Install the upper comp...

Page 118: ...e sure the tool is installed with these tabs facing down toward the engine The compres sion bands will also be toward the lower portion of the ring compressor If the tool is used incorrectly the tool piston or piston rings could be damaged NOTICE The mark on the top of the piston must face the front of the engine block When assembled the flanges on the connecting rod and connecting rod cap should ...

Page 119: ...mely important not to damage the surface of the crankshaft connecting rod journal during installa tion Be careful guiding the connecting rod into posi tion on the crankshaft Catastrophic engine failure may result If the crankshaft connecting rod journal is damaged during installation and left uncorrected 6 Remove the J 5239 7 Install the connecting rod caps bearings and nuts a Tighten the nuts eve...

Page 120: ...7 in 10 Install oil pan Oil Pan and OIl Pump on page 74 11 Install cylinder heads Cylinder Head on page 60 12 Install engine in boat Engine Specifications 5 0 Litre on page 139 Engine Coupler Removal 1 Remove engine from boat Engine Specifications 5 0 Litre on page 139 NOTICE If coupler is being replaced due to coupler failure rubber hub of splined hub check engine alignment after installing new c...

Page 121: ...ote position of clamps so they can be installed in original position 6 Lift flywheel housing off engine block and set aside 7 Unscrew six locknuts then pull coupler off flywheel Inspection Inspect the coupler for burnt rubber chunks missing from the rubber or cracks in the aluminum Check for melted rubber around outer di ameter of aluminum If any of these conditions are found replace the coupler 2...

Page 122: ...und and torqued to 10 15 ft lb before installing coupler 2 Tighten nuts in sequence Use a crowfoot wrench and tighten nuts to 40 45 ft lb 54 61 N m 3 Install flywheel housing Place clamps in their original positions and attache coil bracket and power steering cooler Tighten screws to 38 49 N m 28 36 ft lb 4 Place washer lock washer and nut on ground stud Tighten inner nut to 47 54 N m 35 40 ft lb ...

Page 123: ...Workshop Manual Flywheel Removal 1 Engine coupler Engine Coupler on page 116 2 Remove flywheel from crankshaft studs NOTICE If replacing the engine flywheel then NEW flywheel weights must be installed into the NEW engine fly wheel in the same location as the old flywheel weights in the old engine flywheel 3 Note the position of any flywheel weights for assembly if appli cable 20034 188129 64126 ...

Page 124: ...tall flywheel on crankshaft studs 7 Install engine coupler Engine Coupler on page 116 Crankshaft Rear Oil Seal and Housing Remove 1 Remove engine from boat See Engine Removal and Installa tion Workshop Manual 2 Remove engine coupler See Engine Coupler on page 116 3 Remove flywheel See Flywheel on page 119 4 Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing Insert a suit...

Page 125: ... seal housing gasket 9 Discard the crankshaft rear oil seal housing gasket 10 If necessary remove the spring type pin Installation Tools Required J 35621 B Rear Main Seal Installer 1 Install the crankshaft rear oil seal housing retainer stud and tighten to 6 N m 53 lb in NOTICE Always use a NEW crankshaft rear oil seal housing gasket when installing the crankshaft rear oil seal housing 2 Install t...

Page 126: ... amount 2 to 3 drops of clean engine oil to the outside diameter of the crankshaft rear oil seal 12 Install the crankshaft rear oil seal onto the J 35621 B 13 Install the J 35621 B onto the rear of the crankshaft and hand tighten the tool bolts until snug NOTICE Proper alignment of the crankshaft rear oil seal is crit ical Install the crankshaft rear oil seal near to flush and square to the cranks...

Page 127: ...Cylinder Head on page 60 3 Remove oil pan See Oil Pan and OIl Pump on page 74 4 Remove pistons and connecting rods See Piston Connecting Rod and Bearings on page 105 5 Remove timing chain and sprocket See Timing Chain and Sprocket on page 94 6 Remove starter See Starter on page 39 7 Remove engine coupler See Engine Coupler on page 116 8 Mark or identify the crankshaft bearing cap locations directi...

Page 128: ...Meter CAUTION Wear safety glasses NOTICE Use care when handling the crankshaft Avoid dam age to the crankshaft bearing surfaces 1 Clean the crankshaft in cleaning solvent Remove all sludge or restrictions from the oil passages 2 Dry the crankshaft with compressed air 3 Clean the crankshaft bearings in cleaning solvent Wipe the crankshaft bearings clean with a soft cloth NOTICE Do not scratch the c...

Page 129: ... to the oil passages Damage to the threaded bolt holes 6 Inspect the crankshaft balancer key 1 the keyway 2 and the threaded hole 3 for damage Repair or replace the crankshaft as necessary 7 Measure the crank pins for out of round and taper Engine Specifications 5 0 Litre on page 139 8 Use a suitable support to support the crankshaft on the front and rear journals 9 Use the J 7872 in order to meas...

Page 130: ... obtained verify that the correct size crankshaft bearing has been installed Engine Specifications 5 0 Litre on page 139 c Inspect the crankshaft for binding Turn the crankshaft to check for binding If the crankshaft does not turn freely then loosen the crankshaft bearing cap bolts one bearing cap at a time until the tight crankshaft bearing is located Burrs on the crankshaft bearing cap foreign m...

Page 131: ...nces For this reason in one journal bore you may use one half of a standard crankshaft bearing with one half of an undersize crankshaft bearing NOTICE Do not use the plastic gauge method to measure con necting rod bearing clearances The plastic gauge method for measuring connecting rod bearing clear ances will result in unreliable measurements Use only the micrometer method to correctly determine ...

Page 132: ...ameter ID at two points 90 degrees apart Average the measurements 8 In order to determine the bearing clearance subtract the aver age journal diameter from the average bearing inside diameter 9 Compare the crankshaft bearing clearance to the specifica tions See Engine Specifications 5 0 Litre on page 139 10 If the crankshaft bearing clearances exceeds specifications install the new crankshaft bear...

Page 133: ...English 09 2007 129 Engine 5 0 5 7 Litre 2 Install the crankshaft 3 Install the gauging plastic the full width of the journal 4 Install the crankshaft bearings into the crankshaft bearing caps 317351 500655 317295 ...

Page 134: ...d However if a crankshaft bearing is being fitted to an out of round 0 0254 mm 0 0010 in maxi mum crankshaft bearing journal be sure to fit to the maxi mum diameter of the crankshaft bearing journal If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal is excessively out of round the interference between the crankshaft bearing and the crank shaft bearing jo...

Page 135: ...Meter 1 Install the crankshaft bearings into the engine block 2 Apply clean engine oil to the crankshaft bearings 3 Apply clean engine oil to the crankshaft bearing journals 4 Install the crankshaft 5 Install the crankshaft bearings into the crankshaft bearing caps 6 Apply clean engine oil to the crankshaft bearings 317292 317351 317295 ...

Page 136: ...This will align the crankshaft rear bearing thrust surfaces b With the crankshaft pushed forward insert a feeler gauge between the crankshaft and the crankshaft rear bearing thrust surface to measure the clearance Crankshaft end play 0 05 0 20 mm 0 002 0 008 in 14 Rotate the crankshaft in order to check for binding A bent crankshaft or lack of proper crankshaft bearing clearance may cause binding ...

Page 137: ...e Engine Coupler on page 116 23 Install starter See Starter on page 39 24 Install engine in boat See Removal and Installation Workshop Manual Recondition Engine Block Engine Block Plug Removal 1 Remove the engine oil pressure sensor and fitting 2 Remove the dowel straight pins if required 3 Remove the S type pin 333649 182855A ...

Page 138: ... and left rear top engine block oil gal lery plugs 6 Remove the expansion cup plug camshaft rear bearing hole and discard 7 Remove the engine block oil gallery plugs front from the engine block and discard Insert a 3 8 x 26 in rod into the rear oil gallery holes in order to drive out the front engine block oil gallery plugs 69847 182841 8 8 mm 0 348 182854 0 110 mm 0 004 ...

Page 139: ...ing locator if required 9 Remove the engine block core hole plugs a Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket b Use a suitable tool in order to pull the engine block core hole plugs from the coolant jacket c Discard the engine block core hole plugs 334323 500648 ...

Page 140: ...ngine block spray or wipe the cylinder bores and the machined surfaces with clean engine oil 9 Inspect the following areas Coolant jackets 3 for cracks Cylinder bores 1 for scratches or gouging Valve lifter bores 2 for excessive scoring or wear Threaded holes 4 for damage Crankshaft bearing webs 5 for cracks Crankshaft bearing caps 6 and the crankshaft bearing bores 7 for damage The crankshaft bea...

Page 141: ...ne marks will be remove with the fine grade stones Perform the final honing with a fine grade stone and hone the cylinder bore in a crosshatch pattern at 45 65 degrees to obtain the proper clearance 2 During the honing operation thoroughly check the cylinder bore Repeatedly check the cylinder bore fit with the selected pis ton All measurements of the piston or cylinder bore should be made with the...

Page 142: ...peration measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline 2 Thoroughly clean the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar 3 Follow the instructions furnished by the manufacturer regarding the use of the boring equipment 4 When boring the cylinders make sure all the cranks...

Page 143: ...be Lift Intake 6 97 7 07 mm 0 274 0 278 in Runout maximum 0 065 mm 0 0026 in Connecting Rod Connecting Rod Bearing Clearance Production 0 033 0 078 mm 0 0015 0 0031 in Connecting Rod Bearing Clearance Service 0 025 0 063 mm 0 0010 0 0025 in Connecting Rod Side Clearance 0 15 0 68 mm 0 006 0 027 in Connecting Rod Journal Diameter 53 304 53 334 mm 2 0986 2 0998 in Connecting Rod Journal Taper Produc...

Page 144: ...t Runout at Rear Flange 0 038mm Max 0 0015 in Max Cylinder Bore Diameter 94 894 94 947 mm 3 7360 3 7381 in Out of Round Production 0 025 mm Max 0 0010 in Max Out of Round Service 0 05 mm Maximum 0 002 in Maximum Taper Production Relief Side 0 025 mm Max 0 0010 in Max Taper Production Thrust Side 0 012 mm Max 0 0005 in Max Taper Service Limit 0 025 mm Max 0 0010 in Max Cylinder Head Surface Flatnes...

Page 145: ...m 0 002 0 009 in Valve System Valve Face Angle 45 Degrees Valve Head Edge Margin 0 79 mm Minimum 0 031 in Minimum Valve Lash Rotate the Valve Rocker Arm Nut Clockwise 360 1 turn from Zero Lash Valve Lifter Hydraulic Roller Type Valve Rocker Arm Roller Pivot Type Valve Rocker Arm Ratio 1 5 1 Valve Seat Angle 46 Degrees Valve Seat Runout 0 05 mm Max 0 002 in Max Valve Seat Width Exhaust 1 65 2 49 mm...

Page 146: ...ance Intake Service 0 025 0 094 mm 0 0010 0 0037 in Valve Stem Diameter 8 661 8 679 mm 0 3410 0 3416 in Valve Stem Oil Seal Installed Height Measured from the Top of the Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem Oil Seal 1 2 mm 0 03937 0 07874 in Engine Mechanical Specifications 5 0 litre Application Metric English ...

Page 147: ...obe Lift Intake 6 97 7 07 mm 0 274 0 278 in Runout maximum 0 065 mm 0 0026 in Connecting Rod Connecting Rod Bearing Clearance Production 0 033 0 078 mm 0 0015 0 0031 in Connecting Rod Bearing Clearance Service 0 025 0 063 mm 0 0010 0 0025 in Connecting Rod Side Clearance 0 15 0 68 mm 0 006 0 027 in Connecting Rod Journal Diameter 53 304 53 334 mm 2 0986 2 0998 in Connecting Rod Journal Taper Produ...

Page 148: ... Runout at Rear Flange 0 038mm Max 0 0015 in Max Cylinder Bore Diameter 101 618 101 643 mm 4 0007 4 0017 in Out of Round Production 0 025 mm Max 0 0010 in Max Out of Round Service 0 05 mm Maximum 0 002 in Maximum Taper Production Relief Side 0 025 mm Max 0 0010 in Max Taper Production Thrust Side 0 012 mm Max 0 0005 in Max Taper Service Limit 0 025 mm Max 0 0010 in Max Cylinder Head Surface Flatne...

Page 149: ...ce 0 046 0 100 mm 0 0018 0 0039 in Valve System Valve Face Angle 45 Degrees Valve Head Edge Margin 0 79 mm Minimum 0 031 in Minimum Valve Lash Rotate the Valve Rocker Arm Nut Clockwise 360 1 turn from Zero Lash Valve Lifter Hydraulic Roller Type Valve Rocker Arm Roller Pivot Type Valve Rocker Arm Ratio 1 5 1 Valve Seat Angle 46 Degrees Valve Seat Runout 0 05 mm Max 0 002 in Max Valve Seat Width Ex...

Page 150: ...ance Intake Service 0 025 0 094 mm 0 0010 0 0037 in Valve Stem Diameter 8 661 8 679 mm 0 3410 0 3416 in Valve Stem Oil Seal Installed Height Measured from the Top of the Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem Oil Seal 1 2 mm 0 03937 0 07874 in Engine Mechanical Specifications 5 7 litre Application Metric English ...

Page 151: ...ft Pulley Bolt 58 43 ft lb Crankshaft Rear Oil Seal Housing Bolt and Nut 12 106 in lb Crankshaft Rear Oil Seal Housing Retainer Stud 6 53 in lb Cylinder Head Bolt Preferred Method All Bolts First Pass in Sequence 30 22 ft lb Long Bolts Final Pass in Sequence 75 Degrees Medium Bolts Final Pass in Sequence 65 Degrees Short Bolts Final Pass in Sequence 55 Degrees Cylinder Head Core Hole Plug 20 15 ft...

Page 152: ...ning Switch 16 12 ft lb Exhaust Manifold Bolt to Engine First Pass 15 11 ft lb Final Pass 30 22 ft lb Exhaust Riser Bolt to Exhaust Manifold First Pass 15 11 ft lb Final Pass 36 27 ft lb Circulating Water Pump Pulley 32 24 ft lb Generator and Drive Belt Tensioner Bracket Bolt to Engine 36 27 ft lb Generator and Drive Belt Tensioner Bracket Stud Nut 32 24 ft lb Ground Wire Nut on Flywheel housing 8...

Page 153: ... Pump Cover Bolt 12 106 in lb Power Steering Pump Bolt 50 37 ft lb Spark Plug Initial Installation NEW Cylinder Head 30 22 ft lb All Subsequent Installations 15 11 ft lb Throttle Body Stud 9 80 in lb Upper Intake Manifold Stud First Pass 5 44 in lb Final Pass 9 80 in lb Valve Lifter Pushrod Guide Bolt 16 12 ft lb Valve Rocker Arm Bolt 30 22 ft lb Valve Rocker Arm Cover Bolt 12 106 in lb Water Pump...

Page 154: ...il Gallery Plug Sealant 1141570 Engine Coolant Temperature ECT Sensor Sealant 1141570 Engine Coolant Temperature ECT Gauge Sensor Sealant 1141570 Engine Oil Pressure Sensor Sealant 1141570 Engine Oil Pressure Sensor Fitting Sealant 1141570 Engine Oil Supplement Lubricant 1052367 GM Part No Exhaust Manifold Bolt Stud Threadlock 1161053 Expansion Cup Plug Camshaft Rear Bearing Hole Sealant 1141570 L...

Page 155: ...i Model Item Specification 5 0GXi 5 0OSi 5 7Gi 5 7GXi 5 7OSi 5 7OSXi Low Pressure Fuel Pump 8 PSI 4 55 kPa 27 High Pressure Fuel Pump 50 60 PSI 2 344 413 kPa 13 Oil Capacity 5 qts w o filter 6 with filter Idle RPM 600 RPM Full Throttle 4600 5000 RPM Ignition Timing 10 BTDC set by calibration not adjust able Spark Plug Volvo Penta P N 3861632 Oil Pressure 6 30 PSI 41 207 kPa 800 RPM 40 60 PSI 276 4...

Page 156: ...ecial Tools J 3049 A Valve Lifter Remover J 7872 Magnetic Base Dial Indicator J 5239 Connecting Rod Bolt Guide Set J 8001 Dial Indicator J 5590 Crankshaft Gear Installer J 8037 Piston Ring Compres sor J 5825 A Crankshaft Gear Remover J 8062 Valve spring compres sor head off the engine ...

Page 157: ...uge J 8089 Carbon removing brush J 24086 C Piston Pin Remover Installer Set J 9666 Valve Spring Tester J 24270 Ridge Reamer J 21882 Oil Suction Pipe Installer J 33049 Camshaft Bearing Service Kit J 23523 F Balancer Remover and Installer J 35621 B Crankshaft Rear Oil Seal Installer General Motors Special Tools ...

Page 158: ...20 Camshaft Lobe Lift Indicator J 5802 01 Rocker Arm Stud Remover J 41240 Fan Clutch Remover and Installer J 42073 Valve Stem Seal Installer J 23738 A Vacuum pump J 6880 Rocker Arm Stud Installer o J 28428 E High Intensity Black Light Kit General Motors Special Tools 0 30 50 10 20 40 60 70 80 90 ...

Page 159: ... 35468 Engine Front Cover Aligner and Oil Seal Installer J 3936 03 Piston Ring Groove Cleaner J 5892 D Valve Spring Compres sor J 5715 or J 6036 Reamer J 22794 Spark Plug Port Adapter Volvo Penta Special Tool 888863 Distributor hold down tool J 43276 Clutch Pilot Bearing Remover General Motors Special Tools ...

Page 160: ...ore Tool Division For additional service information not covered in this manual obtain the appropriate Chevrolet Engine Service Manual from Helm Inc P O Box 07130 Detroit Ml 48207 800 782 4356 http www helminc com Material Required Molykote Lubricant Permatex No 2 Volvo Penta Gasket Sealing Compound P N 1161059 GM Super Engine Oil Supplement 3M Adhesive Plastigage Green RTV Sealer API SJ SAE 30 He...

Page 161: ... Shift System S 3 Sterndrive Throttle Control System S 4 Sterndrive Steering System S 5 Sterndrive Fuel Electrical System S 7 Part B Marine Products and Safety of People Who Fix Them S 11 Handling Engines S 11 Handling Lead Acid Batteries S 12 Gasoline Handle with Care S 13 Hazardous Products S 14 ...

Page 162: ...t A word about fasteners plain special all screws nuts washers and bolts Do Not Substitute Fasteners Don t substitute unless you know they are the same in all characteristics Second Special locking screws and nuts are often used to attach steering and remote control components to the sterndrive When you remove any part from the sterndrive keep track of special screws and nuts Don t mix with other ...

Page 163: ...ction intended by operator Propeller is still powered turning unknown to operator or engine will start in gear boat will move unexpectedly How Can Loss of Shift Control be Minimized In pre delivery inspection and when servicing Read understand and follow manufacturers instructions Closely follow the warnings marked with Assemble parts and make adjustments carefully Test your work Don t guess Make ...

Page 164: ...ller What Could Happen If operator cannot slow the engine to idle RPM and shift into neutral stop propeller operator could panic and lose control of boat How Can Loss of Throttle Control be Minimized In pre delivery inspection and when servicing Read understand and follow manufacturers instructions Closely follow the warnings marked with Assemble parts and make adjustments carefully Test your work...

Page 165: ...erly must be adjusted properly must be lubricated What Could Happen if steering system comes apart boat would turn suddenly and circle passengers and or operator may be thrown into water and could be hit if steering jams operator may not be able to avoid obstacles Operator could panic if steering is loose operator may not be able to maintain a true course and could result in loss of boat control ...

Page 166: ...area must not be restricted Steering components must not bind Why Possible jamming of steer ing system In pre delivery inspection and when servicing Power steering parts and push pull cable must be free to move in order to actuate power steering valve when operator turns steering wheel Engine stringer must not interfere with power steering pump and pul ley Maintain proper belt tension Check for da...

Page 167: ...ion Be Minimized Read understand and follow manufacturers instructions Closely follow the warnings marked with Do not substitute fuel or electrical parts with other parts which may look the same These parts are designed and manufactured to meet special U S Coast Guard safety regula tions to prevent fire and explosion If you work on marine engines you must understand these U S Coast Guard requireme...

Page 168: ... job The other half is your job It s time for replacement BEFORE sparks and or fuel leaks occur Replace parts carefully Make sure nuts and bolts are tight especially when they anchor electrical wires to prevent sparking If lock washers are specified use them No short cuts or missing parts with either of these CRITICAL safety related systems When refueling always ground fuel nozzle to the inlet fit...

Page 169: ...gine Open the compartment and use your nose Don t gamble Backfire flame arrestor must be in place and securely attached to the air intake Do not alter the backfire flame arrestor If loose damaged or altered an engine backfire may pass through the flame arrestor assembly into the engine compartment If fumes are present in compartment fire and explosion could result ...

Page 170: ...nd understanding instructions Reading and understanding warnings marked with Putting parts together correctly Making correct adjustments Testing you work and making sure Worn or damaged parts are replaced Replaced parts are like originals in every way Customer is told of things which need attention But do you really want the alternative ...

Page 171: ...gine compartment cover is a guard When you remove the cover guard to work on the engine remember Loose clothing open shirt sleeves neckties long hair jewelry rings watches brace lets hands arms belts can be caught by moving belts or spinning pulleys Handle high voltage ignition components carefully They can shock you and may cause you to recoil into moving parts Two people working together on a ru...

Page 172: ...hammers They don t chip off as easily as steel hammers If spilled or splashed on any part of body If solution gets into eyes Wash and see a Doctor fast Wash with lots of water Charging Lead Acid Batteries Attach and remove these cables with charger unplugged from 110 volt wall socket Prevents shocks if the charger is defective Observe correct polarity when con necting these charger leads Always ch...

Page 173: ...100 Parts Air If the air around you is quiet the pilot light in the heater may ignite the heavy fumes before your nose ever smells the fumes Gasoline Handle With Care When you smell any odor of gasoline explosion is possible Gasoline fumes are heavier than air and will sink to the lowest point in the boat or room and will stay there waiting Store in sturdy sealed gas can and keep outside What Can ...

Page 174: ...curious and will try to taste everything so yummmmmmmmmmm Keep containers away from children Know items in and around repair area which can ignite gasoline fumes Control them if fumes are smelled Matches cigarettes torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights furnace dryer water heater How many of these are in you...

Page 175: ......

Page 176: ...VPA 7748089 English 09 2007 ...

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