Volvo Penta V8-225 Page 54 Operator'S Manual Download | Manualshive

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Troubleshooting

Engine Troubleshooting Guides

The following troubleshooting guide is provided to help
you isolate a malfunction of one or more of your boat’s
systems. After determining which systems are affected
by the malfunction, refer to the individual system trou-
bleshooting charts to isolate the specific cause.

This guide was written to help you trace the symptoms
of the trouble to the source, without having to read
through and prove every possibility. Much of the infor-
mation here will be familiar to well informed mechanics.

The greatest aid to solving a service problem is infor-
mation. Start gathering information and keep a detailed
record of the symptoms of the malfunction. Keep a
record of pertinent facts, such as:

•

When did this trouble start?

•

How was the boat loaded?

•

Did the trouble occur suddenly or did it become
apparent gradually?

Whether servicing the boat’s systems yourself or hav-
ing your product serviced by a certified Volvo Penta
dealer, you will need this record of information to iden-
tify potential causes of the malfunction.

Keep in mind the fundamentals of engine operation, all
of the following must be present for the engine to run:

•

COMPRESSION - Mixture inducted into cylinder
and compressed.

•

SPARK - Proper intensity at the proper time.

•

FUEL - Proper mixture of air and fuel.

•

EXHAUST - Clear of any obstructions.

•

COOLING - water is needed to cool the engine.

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47706149 09-2015 © AB VOLVO PENTA

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Summary of Contents for V8-225

Page 1: ...OPERATOR S MANUAL V8 225 V8 270 V8 300 V8 320 ...

Page 2: ......

Page 3: ... and Controls 16 Optional 22 Starting 24 Operation 28 Engine Shutdown 44 In Case of Emergency 49 Troubleshooting 52 Maintenance Schedule 68 Maintenance 73 Storage 98 Technical Data 101 Operator s Manual Order 110 Alphabetical index 111 47706149 09 2015 AB VOLVO PENTA 1 ...

Page 4: ...mers employees and the community By embracing care of the environment as a core value Volvo demon strates its understanding of the environmental impact its products have upon nature and the shared urban and rural surroundings Volvo Penta continually commits a considerable part of its development resources toward minimizing the environmental impact of its products Examples of areas where we are alw...

Page 5: ...or s manual is delivered with your power package However if you are unsure whether you have the cor rect manual or would like to purchase a new manual please visit the publication section of our website vol vopenta com Use your serial number at the publica tion search the site will provide you with the correct manual The publication search will also provide you with all of the other publications t...

Page 6: ...detailed information see your authorized Volvo Penta dealer or the service manuals for your package Foreword 4 47706149 09 2015 AB VOLVO PENTA ...

Page 7: ...s DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury Look for the safety alert symbol and Danger Warning and Caution messages in th...

Page 8: ... is legally required to know and follow the current navigation and safety laws Make sure you know the laws that apply to you and the waters in which you are boating Contact the relevant authorities for specifics We strongly recommend you take a course in safe boating Contact your local boating organization to find available courses Always observe the following minimum precau tions while boating In...

Page 9: ...operate the engine compartment bilge blower as recommended by the boat manufacturer before starting the engine Do not operate the engine without a fully functioning bilge blower Safety messages covering gasoline and fuel vapors encountered while working on your boat or engine are provided in the appropraite locations throughout the manual Look for the saftey alert symbol triangle DANGER A rotating...

Page 10: ...ese hazards are covered in the procedures look for the safety alert symbol triangle A key component of safety on a boat is the condition of the boat and its systems including the power pack age A boat that has not been regularly maintained or that has neglected mechanical problems is more likely to break down potentially leaving its passengers in dangerous situations P0018155 P0018148 Safety Infor...

Page 11: ... 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 monoxide is ...

Page 12: ... is not breathing perform rescue breathing or approved cardiopul monary resuscitation CPR as appropriate until medical help arrives Prompt action can make the difference between life and death Evacuate the area and move affected per son s to a fresh air environment Observe the victim s Administer oxygen if available Investigate the source of CO and take corrective action Marine CO Detection System...

Page 13: ... 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 monoxid...

Page 14: ...s 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 As shown...

Page 15: ...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 16: ...our 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 days per year If your engine breaks down the VAS coordinator will quickly locate your nearest dealer If you need a tow parts o...

Page 17: ...r call 1 800 522 1959 US only 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 Penta dealer Volvo Penta on the Internet is the web site to visit Additionally you will find a wealth of infor mation related to our ...

Page 18: ...dealer Ignition Lock Ignition switch Usually located at the helm near the gauges Key positions control power to accessories power to the electrical system and starting the engine A Power is provided to run accessories Ignition is OFF and engine is OFF Not present on all ignition switches O Off position the key can be inserted or removed I Ignition is ON and engine is OFF System energized S START p...

Page 19: ... pressure reading Lower oil pres sure is normal and should be expected at idle after a sustained cruise 5 Voltmeter Shows the voltage in the electrical system When the engine is running alternator charge voltage is shown normal reading is approximately 14 volts When the engine is off key on battery voltage is shown normal voltage is approximately 12 volts 6 Fuel Gauge Provides fill level of fuel t...

Page 20: ...rive is equipped with a power trim system as standard equipment The power trim allows the operator to raise and lower the drive from the helm This changes the angle of the drive and its thrust in relation to the boat bottom This is called trimming and provides the following benefits Improves acceleration to planing Keeps the boat on plane at reduced throttle settings Improves fuel economy Provides...

Page 21: ...s operate the same as the buttons detailed above The top button is an override that is used to enter beach and tilt mode Trim Gauge Trim gauges show the relative position of the boat s bow based on the drive trim angle The digital instrument shows the trim angle in numbers and the trim range TRIM and beach range BEACH in text The higher the number the higher the bow position The analog trim instru...

Page 22: ...afety switch to ensure that the engine cannot be started when the drive is in gear If your boat does not have Volvo Penta controls ask your dealer for operating instructions for your remote control Operation and function may differ from the Volvo Penta controls WARNING Risk of personal injury Read the procedures and safety messages in Operation before operating these controls Control mechanisms an...

Page 23: ...e 4 Turn the tension screw A clockwise to increase drag and counter clockwise to decrease drag on the control arm 5 Reinstall the plastic cover and remote control lever Side Mount Remote Controls 1 Make sure the engine is turned off by removing the key from the ignition switch 2 Remove the plastic cover that shields the remote control mechanism 3 Place the control lever in reverse just beyond the ...

Page 24: ...rce on your boat the pier or other boats in close proximity to yours NOTICE ACPS is designed for salt water applications only using the system in fresh water while harmless will not protect your drive from corrosion The ACPS control module will be mounted near the rear of the engine The module has green G and red R LED indicator lights The lights indicate the status of the system 1 Green LED only ...

Page 25: ...ormal boat operation should be minimal Keep the following in mind if your engine has this system The extra hoses and the accessory add capacity to the cooling system It may take longer to heat up the engine For freshwater cooled engines the extra capacity must be accounted for when replacing the coolant For seawater cooled engines the system must be drained during freezing conditions NOTICE Risk o...

Page 26: ...to start an engine This may cause an explosion in the inlet manifold Before you to start your engine be sure to perform the inspection items provided in the daily checklist located in Maintenance Schedule 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 page 45 for instructions Before using your boat see Stati...

Page 27: ...turer Frequently check boat s bilge area for gasoline fumes 3 Check the bilge for excessive water accumulation Bilge water will run to the transom during acceler ation and could damage the starter or other engine components 4 Open the fuel valve B if equipped 5 Check the engine oil level top off if needed 6 If your engine is equipped with a freshwater cooling system check the coolant antifreeze le...

Page 28: ...your boat If your boat does not have an audible alarm available we strongly recommend that you contact your dealer to have one installed Starting the Engine 1 Move the control handle to the NEUTRAL detent position N 2 Turn the ignition switch to START S 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 ...

Page 29: ...the lever to the FULL THROTTLE B posi tion 3 Try to start the engine turn the ignition switch to S Start If the engine does not start quickly release the key and then try again 4 After the engine starts move the throttle back to the neutral position to return to normal operating mode 21183 1 P0016544 Starting 47706149 09 2015 AB VOLVO PENTA 27 ...

Page 30: ...w Stop the engine immediately and investigate Operating the engine with low oil pressure will damage the engine See Troubleshooting page 56 Normal operating temperatures are Seawater cooled 150 F 66 C Freshwater cooled 140 190 F 60 88 C WARNING Risk of fire Immediately investigate any engine over heat situation The engine can catch fire if the overheat is prolonged or severe Correct the overheat s...

Page 31: ...s mentioned above and the corrective steps refer to Troubleshoot ing Maneuvering Safety precautions for boat operation DANGER A rotating propeller can cause serious injury Never boat near people who are swimming or where there is a risk that there are people in the water The engine must be off if there is anyone in the water near the boat Check that nobody is in the water before shifting the drive...

Page 32: ... drive in to gear 1 The control lever must be in the neutral position N to start the engine 2 To go forward Move the control lever forward from neutral to the forward gear engagement detent position F Throttle movement begins after forward gear engagement Move the control lever forward to increase speed 3 To go in reverse Move the control lever back from neutral to reverse gear engagement detent p...

Page 33: ...vating the emergency stop switch at any speed above idle will allow water to be ingested into the engine causing serious engine damage If the lanyard is too long do not cut and re tie the lan yard Shorten by looping or knotting the lanyard CAUTION Care must be taken to avoid accidentally pulling the lanyard during boat operation Unexpected loss of for ward motion will occur which could cause occup...

Page 34: ...er propeller size If the engine will not reach the WOT range the boat may be overloaded or over propped and should be taken to the dealer for correction Power Trim Tilt Trim Controlling the trim system is an important part of maneuvering a boat Power trim provides this control at the helm of the boat allowing the operator full and easy control of the trim system Power trim is normally used as part...

Page 35: ...drive can be trimmed past the trim range and into the Beach and Tilt positions Press the top and center buttons at the same time to enter these trim ranges Trim Ranges The trim gauge shows the relative position of the boat s bow based on the drive trim angle Trim is divided in to the three trim ranges described below The digital gauge is shown in the illustrations an analog gauge provides the same...

Page 36: ...ge NOTICE Possible engine damage Maximum safe engine speed when running in beach range is 1000 rpm If the engine is running make sure the drive s coolant inlet is under water when trimming to beach range Tilt Tilt range for all drives is any angle over 30 This range is used for raising the drive completely an example is when putting the boat on the trailer NOTICE Do not operate run the engine in t...

Page 37: ... of the trim system trim in or out This is worsened with speed and changing sea conditions Avoid excessive trim in or out If you experience boat instability or high steering torque set the trim to neutral and return to port at reduced speed See your Volvo Penta dealer to cor rect the situation Trim Operation during Takeoff Trim is used to get the boat on plane when taking off from a stand still or...

Page 38: ...own position B is normally used for accel eration onto plane operating at slow planing speeds and running against a rough sea WARNING Avoid excessive trim in bow down when operating at speed and or in rough seas The boat s bow may dive in to oncoming waves causing the boat to bow steer or spin rapidly possibly injuring the boat s passengers Be aware of these undesirable conditions that can occur w...

Page 39: ...desired direction Once the lever is out of the neutral position you may release the button The neutral interlock will automatically re engage when the control lever is returned to the NEUTRAL position Throttle Only The gear shift can be disengaged so that the control lever affects only the engine throttle speed To disengage the shift mechanism move the control lever to the neutral position press t...

Page 40: ...is condition occurs look for possible causes and fix them if possible If the power steering system cannot be corrected on board proceed at a reduced speed You will be able to steer the boat but with increased effort See your authorized Volvo Penta dealer as soon as possible to correct your power steering system At slow speeds no wake your boat may tend to wan der due to wind and current This is no...

Page 41: ...ended periods with only one engine running Both engines must be running when under way If only one engine is running water may be forced back through the exhaust of the engine that is not running causing serious engine damage NOTICE Do not attempt to run the boat on plane if operating on a single engine operating with a single engine at full throttle could cause engine or transmission damage If ru...

Page 42: ...t the boat to be unused for two months or more it must be prepared for this shut down period See Storage page 98 When the drive is stored out of the water the sacrificial anodes oxidize on the surface This prevents them from functionally correctly when placed back in the water Before using the boat again the sacrificial ano des on the drive and shield must be cleaned with emery paper to remove any...

Page 43: ... cause freezing NOTICE When temperatures drop below freezing failure to completely drain the cooling system will result in serious damage 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 in Draining the Engine Shallow Water Operation WARNING The sudde...

Page 44: ...nderwater vegetation or other submerged debris This may lead to overheating and engine damage High Altitude Operation Volvo Penta EFI engines have programmed altitude compensation however there may be a slight per formance loss at altitudes above 5000 feet due to lower air density If you are boating above 5000 feet for a short time a lower pitch propeller will restore some of the lost performance ...

Page 45: ... A boat travelling at a speed of approximately 70 M P H 60 knots covers about 101 feet 30 meters in 1 sec ond The faster you go the quicker things will happen High speed driving requires a lot of water and a good distance from possible hazards Always allow for ade quate reaction time Always reduce speed when visi bility is reduced for whatever reason When driving make sure that all passengers are ...

Page 46: ...in the boat due to sudden changes in boat movement Stop the Engine 1 The control lever must be at NEUTRAL N 2 Let engine return to idle Allow the engine to run at low idle in neutral for a few minutes after operations are completed This allows engine temperatures to equalize This is especially important when the engine has been run at high rpm or under heavy load just prior to shut down 3 Turn ign...

Page 47: ...e 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 circulates throughout the engine 6 After engine is flushed shut down the engine NOTICE Drain the engine if freezing temperatures are expected For details on draining t...

Page 48: ...d boat are being moved During transport be aware of high spots or dips in the roadway such as railroad crossings low street gutters large potholes or other uneven road surfa ces Be careful when backing The drives could strike the road or ground causing damage When you have reached your destination if the boat will be stored on the trailer the drive should be trim med down to a level position Flush...

Page 49: ...ill provide for complete drainage of the block and manifold If the engine is not level some water may remain trapped When draining the starboard manifold take care to direct the drained water away from the starter to pre vent water damage to the starter 2 After the water has completely drained reinstall the drain plugs and tighten securely 3 Loosen the hose clamps and remove the hoses from the raw...

Page 50: ... starboard elbow 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 3 Loosen the hose clamps and remove the hoses from the raw water pump 4 Loosen the heat exchanger anode and allow water to drain After water has stopped draining reinstall the anode See Replacing ...

Page 51: ...nding The safety of the boat s occupants should be a high priority The circumstances of the impact including the speed any injuries or any damage done should be factored into the course of action taken to protect the occupants and then minimize any further damage to the boat NOTICE If there are problems at any of the following steps call for assistance to move the boat to a location where it can b...

Page 52: ... in reverse operate at low RPMs to reduce the potential for damage To prevent galvanic corrosion any paint damage on the drive and propeller should be repaired before launching the boat again Tie Rod Applies to twin engine boats with mechanical not elec tric steering The tie rod connects the tiller arms of the two drives It is mounted inside the boat at the rear of the engines Check the tie rod if...

Page 53: ...ries 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 vol atile DANGER Never interchange the positive and negative poles on the batteries Risk of arcing and explosion 1 Check that the auxiliary battery has the same volt age as the engine electrical system 2 Connect the red positive cable to the plus ter mi...

Page 54: ...athering information and keep a detailed record of the symptoms of the malfunction Keep a record of pertinent facts such as When did this trouble start How was the boat loaded Did the trouble occur suddenly or did it become apparent gradually Whether servicing the boat s systems yourself or hav ing your product serviced by a certified Volvo Penta dealer you will need this record of information to ...

Page 55: ... dirty insulator Low battery voltage Call for assistance or see Volvo Penta authorized dealer Fuel System Check Fuel level Fuel shutoff and multiple tank valves are open and operating properly External fuel filter canister clogged Quantity and condition of fuel in boat tank Operation and flow capacity of boat anti siphon valve Fuel tank vent is unrestricted Fuel tank pick up screen is clean Correc...

Page 56: ...horized dealer Cooling System Check Supply pump Loose belts and or pulleys See Cooling System Call for assistance or see Volvo Penta authorized dealer Mountings Check Loose broken or worn engine mounts Loose lag screws holding mounts to stringer Call for assistance or see Volvo Penta authorized dealer Alternator Check Loose pulley see dealer Noise from bearings see dealer Call for assistance or se...

Page 57: ...upply pump Water leaks on pressure side of supply pump If equipped with a heat exchanger check to be sure that it is free of debris Call for assistance or see Volvo Penta authorized dealer Engine Dies Out Refer to 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 l...

Page 58: ...r 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 to jump start the engine Refer to Starting Using Auxillia...

Page 59: ...e can usually be traced to differences between actual conditions and the test conditions The condition of the hull also influences performance See Hull Weight and Boat Bottom that follow Hull Weight Total boat weight is an important factor in performance This is a combination of the boat and the passengers and gear that are on the boat Any increase in boat weight will reduce boat speed To minimize...

Page 60: ...e 3500 RPMs Bring the engine to idle to investigate the problem Use the oil pressure and temperature gauges to verify a problem exists Check the engine dipstick for proper oil level See Troubleshooting page 55 for temperature issues The low oil pressure engine overheat problem must be corrected before the engine will return to nor mal operation If a temperature problem caused the EPM to activate t...

Page 61: ... reaches recommended levels If you are unable to remove oil from the engine make way at reduced speed Correct the oil level as soon as possible If the oil level is not the problem or the alarm continues to sound after adjusting the oil level check to see if there are any additional problems such as engine over heating See the next section for additional informa tion If the problem persists contact...

Page 62: ...Water in Oil and Oil Level OceanX drives are equipped with a sensor that moni tors oil level and quality If the oil level in the drive is low or water is detected in the oil an alarm will sound for one second every sixty seconds If this alarm sounds check the level and quality of the oil in the drive NOTICE Operating the drive with low or poor quality oil could lead to major drive damage If the al...

Page 63: ...is cranking or running If a pump is not working check the fuse and replace if necessary See your Volvo Penta dealer if further service is required The fuel filter C is also mounted to the fuel cell To change the filter see Engine Fuel Filter Replacement page 82 NOTICE A loud whining noise at idle may be due to a restricted fuel filter causing a noisy fuel pump Oper ating the engine with a restrict...

Page 64: ...as a first step in troubleshooting the problem A label on the cover shows the location type size and other information for the relays fuses and breakers Part numbers are also provided The image is an example of one of these labels and may not represent your engine See the cover label on your engine Spare fuses are located on the inside of the fuse box cover Remember to replace any spares that are ...

Page 65: ... by author ized service technician soonB ON A ON YES Engine operates at reduced throttle providing maneuvering speed only operate boat accord inglyD Engine and or emission system should be inspected by authorized service technician as soon as possibleE ON A ON YES YES Engine RPMs limited to idle speed only Return to port as soon as possible Engine and or emis sion system should be inspected by aut...

Page 66: ...ngled in the drive or the trim cylinders Clear the obstruction before proceeding with trimming Steering If you experience difficulty steering the boat check for the following possible problems 1 Check the fluid level in the power steering pump reservoir The level must be between the Min and Max lines 2 Check that all hose clamps on the power steering system are securely tightened 3 Check all fitti...

Page 67: ... surrounding boats Disconnect shore power wait 8 hours and recheck If still present temporarily relocate boat to another area away from the marina and check again Loose or corroded terminals on the electronic unit or battery Clean and tighten connectors Copper bottom paint is in contact with the transom shield Remove paint and ensure there is a 25mm 1 in border between transom shield and bottom pa...

Page 68: ...t 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 heavy items Do not store un...

Page 69: ...ext to and above the manifold B 4 Unplug the end of the hose and allow water to drain down until it has maintained a stable level 5 Measure the vertical distance C from water line D in the hose to the top of manifold B This is the SWL Measurement C should be 13 in 33 cm or greater 6 If the SWL is less than 13 in 33 cm contact your Volvo Penta dealer for information on raising the engine s exhaust ...

Page 70: ...l scheduled maintenance However Volvo Penta may deny you warranty coverage for your emission control system if failure results from abuse neglect improper maintenance or unapproved modifications If emission control system repair is required during the warranty period you are responsible for presenting your engine to a Volvo Penta authorized dealer as soon as the problem exists The warranty repairs...

Page 71: ...ing 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 Exhaust Check f...

Page 72: ...tems 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 servicing your...

Page 73: ...e Replace Engine Check for Campaigns or Recalls Dealer to check serial number on Partner Network Serpentine Belt Wear tension PCV Valve Check Oil and Filter 1 2 3 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 Manifold Anode...

Page 74: ...iscellaneous 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 ation lubricate Remote Control and Shift System Check for...

Page 75: ... Penta engine Non marine electrical and fuel parts do not meet USCG and other requirements for explosion prevention in gasoline fueled boats Use of non marine parts may result in onboard explosions Certain fuel and electrical system components must comply with U S Coast Guard and other regulations for explosion prevention Parts or components that comply with these regulations are designed so they ...

Page 76: ...alities and corrosion inhibitors needed for marine applications Use of these products ensures proper operation and protection of your engine and drive See your Volvo Penta dealer for genuine oils lubricants and coolant Always insist that your dealer use genuine Volvo Penta parts oils and lubricants when servicing your engine and drive Genuine Volvo Penta parts have been designed and approved to me...

Page 77: ...ocks when work ing on electrical systems To disconnect electrical power remove the ignition key turn off the power supply to the engine at the main switches lock the switches or tag the switches to alert others tag all starting positions Disconnect and remove any shore power connections to the boat Reverse the procedure when the maintenance work has been completed Pressure Washing NOTICE Do not us...

Page 78: ...e carried out by an author ized Volvo Penta workshop The engine must not be modified in any way except with accessories and service kits approved by Volvo Penta No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken Seals may only be broken by authorized personnel Otherwise the general instructions contained in this Operator s Manual concerning operation servic...

Page 79: ...ck the indicators located on the automatic tensioner housing When tick marks G and H align the belt is stretched and should be replaced If G is betweeen H and I the belt is good Also check the serpentine belt for Missing chunks Dry rot Exposed cords or excessive fraying Oil or grease Check the pulley surfaces for corrosion A rough pulley surface will quickly wear the belt If you suspect the belt n...

Page 80: ...k will not be accurate If the oil 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 accurate 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...

Page 81: ... use Volvo Penta mineral oil for gasoline engines Adding Oil After Break in Period Check the oil level frequently see Maintenance Schedule for minimum intervals Frequent oil level checks are a good strategy to ensure long engine life Oil level checks help identify engine service issues such as leaks and excessive oil consumption before they become serious Maintain oil level between E add and D ful...

Page 82: ...itch to prevent stray sparks Eliminate all sources of spark DANGER Failure to inspect your work may allow fuel leakage to go undetected This could become a fire or explosion hazard WARNING Risk of fire When carrying out work on the fuel system make sure the engine is cold A fuel spill onto a hot surface or electrical components can cause a fire WARNING Risk of fire Store fuel soaked rags and other...

Page 83: ...sion and oxidation Add the treatment according to the instructions on the label Also use the treatment for offseason storage winterization as part of the fuel treatment process See Fuel Treatment During Storage page 83 Volvo Penta gasoline engines are equipped with a water separating fuel filter see Engine Fuel Filter Replacement page 82 The use of an additional water separating fuel filter betwee...

Page 84: ...sing clean engine oil lightly lubricate the gasket C and inner seal D on the new fuel filter 4 Screw on fuel filter and hand tighten 5 Clean up any spilled fuel As soon as possible remove the old fuel filter con tainers and absorbent rags from the boat Dispose of safely and according to local environmental reg ulations 6 Turn on the main battery switch 7 Run the bilge blower for at least five minu...

Page 85: ...e level of mechan ical skill and knowledge If you do not feel comfortable performing this procedure see your Volvo Penta dealer for assistance Ask the dealer to perform this Fuel Storage Mixture procedure as part of preparing the engine for storage Using a portable outboard engine fuel tank add Fresh fuel enough to run engine 15 minutes Two cycle motor oil 50 1 ratio gas to oil Volvo Penta Ethanol...

Page 86: ...ed to idle and stop the engine 4 Reconnect the boat fuel line to the fuel inlet fitting and check for fuel leaks Do not start engine DANGER Failure to inspect your work may allow fuel leakage to go undetected This could become a fire or explosion hazard Electronic Fuel Injection The electronic fuel injection EFI fuel metering system delivers the correct amount of fuel to the engine under all opera...

Page 87: ...rmostat housing 4 5 Remove thermostat 5 O ring 6 and gasket 7 from intake manifold 8 Discard gasket and thermostat Inspect O ring and if damaged replace 6 Clean intake manifold and thermostat housing sur faces where the gasket makes contact Remove any remnants of the old gasket NOTICE Take care not to drop any debris into the intake manifold Place a rag in the intake manifold to keep debris out re...

Page 88: ...ipped with a freshwater cooling system check the coolant level before each trip If coolant is low add by removing the coolant filler cap B and adding coolant via the fill spout Do not fill above the maximum fill line A WARNING Do not open the coolant filler cap when the engine is hot Steam or hot fluid could spray out causing severe burns Engines covered by this manual are filled at our factory wi...

Page 89: ...t 10º F 6 C lower than the lowest expected tempera ture for the area where the engine will be stored Check the coolant at ambient temperature do not check hot coolant safety and inaccurate reading concerns The coolant solution can be strengthened to protect at lower temperatures by draining half a gallon of coolant from the engine and replacing with a half gallon of full strength antifreeze soluti...

Page 90: ...tem Intake and exhaust system maintenance is limited to checking and inspecting the bellows and clamps on the exhaust system Other work on these systems should be done by your Volvo Penta dealer Exhaust Bellows and Clamps Check the exhaust system according to the frequency defined in the Maintenance Schedule DANGER Risk of carbon monoxide poisoning from a leaking exhaust system Do not operate the ...

Page 91: ... repairs see the Workshop Manual or your Volvo Penta dealer Firing order 1 8 4 3 6 5 7 2 NOTICE When replacing or installing spark plugs plug wires distributor caps or rotors it is critical that the plug wires are reinstalled from the distributor cap to the correct spark plug cylinder If the plug wires are con nected to the wrong cylinder an engine miss fire will occur The miss fire may cause engi...

Page 92: ...rect spark plugs The ignition and fuel management systems of these engines are finely tuned around many factors includ ing the exact specification of the spark plugs After market plugs and plugs from other manufacturers may differ slightly from the specifications of the factory plugs NOTICE Using non factory plugs in your engine could result in poor engine performance and even engine damage See Ma...

Page 93: ...ons during engine start Ventilate the engine compartment before working on batteries or battery connections WARNING Risk of explosion To prevent accidental sparks and control acid and gases emitted by the batteries the batteries should always be mounted in approved marine battery boxes with covers Always make sure the battery is secured and the cover is firmly attached NOTICE Do not disconnect the...

Page 94: ...e until oil is at proper level See drive Workshop Manual 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 dr...

Page 95: ...s required unless trim system performance is poor If system performance is poor contact a Volvo Penta dealer or refer to the Workshop Manual Pitot Tube Speedometer Port The pitot tube located at the leading edge of the drive unit provides pressure input for the speedometer If the pitot tube becomes clogged e g silt sand vege tation the speedometer may stop functioning To clear debris from the pito...

Page 96: ...cations Inspecting Drive Anodes Inspect anodes see Maintenance Schedule for fre quency If an anode is 2 3 its original size 1 3 eroded replace it The amount of erosion on the drive anode is a good indication of the condition of the shield anode If additional electronic or electrical equipment is instal led each item should have an individual anode or grounding device and all grounding devices must...

Page 97: ...le 2 Turn the engine off and allow the oil to settle for at least 30 minutes 3 Remove the gear shift cover using a 12mm socket to loosen and remove the five screws holding it in place 4 Insert the key into the ignition switch O Turn the key one step to the right I to switch on engine sys tem voltage and instrumentation Do not start the engine 5 Move the plastic protector A off off the oil sensor c...

Page 98: ...never you remove or replace a propeller Do not attempt to hold propellers by hand when you remove or install propellers and propeller nuts Serious injury could result NOTICE Never continuously run with a damaged pro peller Running with a damaged propeller can result in drive unit and engine damage NOTICE Propellers must be removed and the shaft re greased according to the frequency provided in the...

Page 99: ...ine If needed add Volvo Penta Power Trim Tilt and Steering Fluid Do not overfill the pump reservoir NOTICE Never fill the steering system with oil of unknown quality Non recommended oil may cause steering operation impairment or component damage Do not allow contaminants to enter the reservoir when checking or filling the oil level P0008601 Maintenance 47706149 09 2015 AB VOLVO PENTA 97 ...

Page 100: ...hort Term Storage Up to two months Flush engine with fresh water Raw Water Cooled Engines Only Drain raw water from manifolds and engine block See Draining the Engine Closed Cooling Engines Only Drain raw water from manifolds Do not drain the engine block See Draining the Engine Closed Cooling Engines Only Check coolant mix for proper level of freeze protection See Checking Engine Coolant for Free...

Page 101: ...e alignment Lubricate shift cables Replace engine oil and oil filter Replace drive oil Fuel system treatment as described in Fuel Treatment During Storage page 83 Raw Water Cooled Engines Only Drain raw water from manifolds and engine block See Draining the Engine Closed Cooling Engines Only Drain raw water from manifolds See Draining the Engine Closed Cooling Engines Only Check coolant mix for pr...

Page 102: ...ery switch in OFF position install battery and attach battery cables Open the fuel shut off valve and check fuel sys tem for leaks Check the flame arrestor and clean if necessary Pump the bilge dry and air out engine compart ment Federal state and or local regulations pro hibit the pumping of oil into any navigable waters Check all oil and fluid levels and fill as necessary Check drive transom shi...

Page 103: ...3 COOLING SYSTEM Thermostat 150 F 66 C 170 F 77 C closed cooling Coolant type Volvo Penta VCS IGNITION SYSTEM Distributor Electronic Spark Timing ignition system Spark plugs Platinum tipped long life Spark plug gap 0 060 inches 1 50 mm Spark plug installation torque 20 ft lb 27 Nm ELECTRICAL SYSTEM Charging system 12 volt 75 amp alternator Starting Battery Minimum 650 Cold Cranking Amps CCA 135 mi...

Page 104: ...engine oils approved for catalytic converters These oils are engi neered to meet all of the requirements of your catalyst engine and are formulated specifically for marine engines These oils are available at Volvo Penta deal ers If the Volvo Penta oils are not available use high quality oil that meets API SM and or ILSAC GF 4 spec ifications Viscosity should be SAE 5W30 or higher example 10W30 10W...

Page 105: ...s not covered by the warranty Ethanol Blended Gasoline Volvo Penta engines are designed to operate on the commercially available fuel approved by the legislation and governmental agencies of all countries where the engines are marketed and sold Volvo Penta gasoline engines are designed to operate on fuel blends which have a higher percentage of gas oline than ethanol Examples are E10 10 ethanol an...

Page 106: ...articles sludge or gums created by improperly handled ethanol fuel is not covered by war ranty Methanol Do not use any gasoline containing methanol in Volvo Penta engines NOTICE Serious engine damage may result from the continued use of fuel containing methanol Any result ing engine damage is not covered by the warranty Cooling System Coolant Engines covered by this manual are filled at our factor...

Page 107: ...equirements Replace the battery with one that has the same or more cold cranking amps and reserve capacity as the battery installed in your boat by the boat builder See Technical Data for your engine for minimum battery requirements 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...

Page 108: ... lubricant NOTICE Whenever you are changing or topping up the oil always check the oil level using the dipstick Lubrication Capacity All SX Models 2 8 quarts 2 7 liters All DPS Models 2 6 quarts 2 5 liters All FWD Models 3 0 quarts 2 8 liters NOTICE If your drive is equipped with a Drive Spacer you will need to add more oil than the recommended amount P0016608 P0020812 Technical Data 106 47706149 ...

Page 109: ...the lines provided below Make a copy of this page and store the information away from the boat NOTICE The identification plates depicted in the illustrations below are samples only The numbers on your identification plates will be different than those shown below Engine Plate 51802 SERIAL NUMBER SALES NUMBER Transom Shield Plate 51804 SERIAL NUMBER PRODUCT NUMBER TYPE Drive Unit Plate 51803 SERIAL...

Page 110: ...the engine decal Your Volvo Penta dealer will have attached these stickers at the time that the transom assembly and drive unit were mounted on your boat and attached to the engine The engine plate is typically located on the port rear side of the engine block The California emission sticker is located on the engine cover The emission control Information sticker is located on the flat outside face...

Page 111: ...SDVOL016 V8 270 201 kW EXVOL006 SDVOL015 V8 300 224 kW EXVOL015 SDVOL016 V8 320 239 kW EXVOL015 SDVOL016 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 Ann...

Page 112: ...to the link below On the web page type in the publication number found in the bottom of this page 7 8 digits http vppneuapps volvo com manual coupon If internet access isn t possible please contact your Volvo Penta dealer All order information is stored internally at AB Volvo Penta and will not be shared with third parties 110 47706149 09 2015 AB VOLVO PENTA ...

Page 113: ... Blended Gasoline 81 103 Exhaust Bellows and Clamps 88 Exhaust Manifold Anodes 89 F Flooded Engine 27 Forward Drive 3 Freshwater System 86 Friction Brake 21 Fuel System 80 103 Fuel Treatment During Storage 83 Fuse and Relay Box 62 G Gauges 17 H High Altitude Operation 42 High Performance Boat Operation 43 Hot Water Outlet 23 Hour Meter 70 I Identification Numbers 107 Ignition Lock 16 Ignition swit...

Page 114: ...1 Starting the Engine 26 Starting Using Auxiliary Batteries 51 Static Water Line 66 Static Water Line Test 67 Steering 64 97 Steering System Operation 38 Stop the Engine 44 Stop the Engine Before Service 75 T Throttle Only 37 Trailering Your Boat 46 Trim Ranges 33 Trim Tilt Motor Protection 36 Twin Unit Steering 39 V Volvo Action Service VAS 14 Volvo Penta Dealer Network 15 Volvo Penta on the Inte...

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