Volvo Penta V6-200 Operator'S Manual Download

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OPERATOR’S MANUAL

V6-200, V6-225

Summary of Contents for V6-200

Page 1: ...OPERATOR S MANUAL V6 200 V6 225 ...

Page 2: ... volvopenta com coupon Se não for possível aceder à internet contacte o seu con cessionário Volvo Penta To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδοση μέσω διαδικτύου http manual volvopenta com coupon Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο παρακαλούμε επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta Данное руководство по эксплуатац...

Page 3: ... and Controls 15 Optional 21 Starting 23 Operation 27 Engine Shutdown 43 In Case of Emergency 48 Troubleshooting 51 Maintenance Schedule 64 Maintenance 69 Storage 95 Technical Data 98 Operator s Manual Order 107 Alphabetical index 109 47706041 07 2014 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: ... the correct manual The publication search will also provide you with all of the other publications that are available for your power package These publications such as workshop man uals and parts catalogs can be purchased for a small fee When seeking assistance from your dealer regarding your power package always provide the serial number for your engine When reading sections of this manual that ...

Page 6: ...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 7: ... 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 8: ...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 9: ...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 10: ... 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 11: ... 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 12: ... 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 13: ...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 14: ...ms 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 discharge t...

Page 15: ...ional informa tion Keep your owner s identification card with you at all times this will facilitate finding parts and providing service when you visit any Volvo Penta authorized dealer Volvo Action Service VAS Volvo Action Service VAS is a consumer breakdown service available 24 hours each day 365 days per year If your engine breaks down the VAS coordinator will quickly locate your nearest dealer ...

Page 16: ...tor on the Volvo Penta s web site or 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 wea...

Page 17: ...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 18: ... 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 19: ...fety messages are covered in Power Trim Tilt page 31 in Operation Do not operate the trim system until you have read that chapter Power Trim Control The trim system is controlled by trim switches located on the shift lever The upper button moves the drive up or away from the transom This trims the drive out Trimming the drive out will raise the bow of the boat in relation to horizontal The lower b...

Page 20: ... the higher the bow position The analog trim instrument shows the bow position based on the current position of the drive This instru ment has three ranges 3 Tilt range 2 Beach range 1 Trim range For an explanation of trim ranges refer to Trim Ranges page 32 Gauges shown are from Volvo Penta Other trim gauges use similar functionality and terminology P0018174 P0018175 Instruments and Controls 18 4...

Page 21: ...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 22: ...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 23: ... 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 sterndrive 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 onl...

Page 24: ...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 25: ...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 44 for instructions Before using your boat see Stati...

Page 26: ...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 27: ...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 28: ...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 26 47706041 07 2014 AB VOLVO PENTA ...

Page 29: ...w Stop the engine immediately and investigate Operating the engine with low oil pressure will damage the engine See Troubleshooting page 55 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 30: ...lems 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 dr...

Page 31: ... 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 32: ...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 33: ...gine 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 of accelerating to help ge...

Page 34: ... that the 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 provide...

Page 35: ...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 tilt...

Page 36: ... 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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...the boat to be unused for two months or more it must be prepared for this shut down period See Storage page 95 When the sterndrive is stored out of the water the sac rificial anodes oxidize on the surface This prevents them from functionally correctly when placed back in the water Before using the boat again the sacrificial anodes on the drive and shield must be cleaned with emery paper to remove ...

Page 42: ...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 You may tilt the drive unit to reduce the draft for shallow water running A as long as you do not exceed 1000 RPM Exceeding 1000 R...

Page 43: ...tional information see Engine Flush High Performance Boat Operation High performance is not only defined by engine size but by a combination of engine power hull design and the size of the boat Depending on the combination of these factors top speed may be much higher than expected High speed operation requires an experienced opera tor who has mastered handling of high performance boats It is advi...

Page 44: ...nce cabin cruiser where one normally moves about during operation Reduce speed consid erably or stop completely if someone needs to move about the boat The driver should always use the Safety Lanyard see Safety Lanyard page 30 The safety lanyard immedi ately shuts off the engine s should the driver be thrown from the driving position Even if the risk of being thrown overboard is practically nonexi...

Page 45: ...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 46: ...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 cir culates 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 the engine see Draining Raw Water Cooled En...

Page 47: ...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 48: ...p the engine level This will provide for complete drainage of the block and manifold If the engine is not level some water may remain trapped NOTICE When draining the starboard manifold take care to direct the drained water away from the starter to prevent water damage to the starter 2 Loosen the hose clamps and remove the hoses from the raw water pump 3 Loosen the hose clamp on the large diameter...

Page 49: ...he engine is not level some water may remain trapped NOTICE When draining the starboard manifold take care to direct the drained water away from the starter to prevent water damage to the starter 2 Loosen the hose clamps and remove the hoses from the raw water pump 3 Loosen the heat exchanger lower end cap If pos sible do not completely remove the screw Loosen enough to allow cap to separate from ...

Page 50: ...oat All of these situations could place the boat s occupants at risk Consider all of these factors when formulating plans to address the impact damage Trim tilt system impact protection is built in to the trim cylinders If an impact occurs while in forward motion the cylinders will allow the drive to kick up thereby helping to minimize boat and drive damage NOTICE There is no impact protection in ...

Page 51: ...ng 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 The boat and drive should be thoroughly inspected before the boat is used again To prevent galvanic corrosion any paint damage ...

Page 52: ...that the auxiliary battery has the same volt age as the engine electrical system 2 Connect the red positive cable to the plus ter minal on the discharged battery and then to the plus terminal on the auxiliary battery 3 Connect the black start cable to the negative terminal on the auxiliary battery and to a place a little distance away from the discharged battery e g the starter motor s negative te...

Page 53: ...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 54: ... 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 55: ...ized 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 see V...

Page 56: ...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 57: ...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 58: ...mance 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 mini...

Page 59: ...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 54 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 60: ... 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 61: ...ealer 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 78 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 restricted filter may damage the pressure regulator or fuel pumps See your Volvo Penta dealer if the pump makes an unu...

Page 62: ...lays in the fuse box Trim Motor Protection If the trim switch is held too long in either full up or down the motor will stop See Trim Tilt Motor Protec tion page 35 Drive Physically Blocked from Moving Check to see if anything has become entangled in the drive or the trim cylinders Clear the obstruction before proceeding with trimming Steering If you experience difficulty steering the boat check f...

Page 63: ...er or 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 bott...

Page 64: ...the boat and engine exhaust will sit lower in the water This raises the water level in the exhaust If you add too much weight the water level will be high enough to allow water inges tion NOTICE Water ingestion damage from over loading is not covered by warranty Consider the static water line of your boat before add ing equipment such as generators appliances coolers and other heavy items Do not s...

Page 65: ...next to and above the manifold B 4 Unplug the end of the hose and slowly 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 ...

Page 66: ...duled maintenance However Volvo Penta may deny you warranty coverage for your emission control system if failure results from abuse neglect improper mainte nance or unapproved modifications If emission control system repair is required during the warranty period you are responsible for presenting your sterndrive engine to a Volvo Penta authorized dealer as soon as the problem exists The warranty r...

Page 67: ...eering 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 Chec...

Page 68: ...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 69: ...Fill Lube Adjust Tighten Clean Change Replace Engine Check for Campaigns or Recalls Dealer to check serial number on Partner Network Serpentine Belt Wear tension 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 ...

Page 70: ...nge Miscellaneous Batteries and Connections Batteries hold charge connections clean and tight Engine Alignment Check General Inspection All engine and drive hard ware clamps screws nuts etc Power Steering Check for proper operation check hoses and components for leaks Power Steering Fluid Check level Steering System Cable s Check for proper oper ation lubricate Remote Control and Shift System Chec...

Page 71: ... 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 72: ...ities and corrosion inhibitors needed for marine applications Use of these products ensures proper operation and protection of your engine and sterndrive 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...

Page 73: ...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 74: ...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 75: ...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 76: ... 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 77: ... 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 78: ...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 79: ...orro 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 79 Volvo Penta gasoline engines are equipped with a water separating fuel filter see Engine Fuel Filter Replacement page 78 The use of an additional water separating fuel filter b...

Page 80: ...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 81: ... moderate level of mechan ical skill and knowledge If you do not feel comfortable performing this procedure see your Volvo Penta dealer for assistance 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 Fuel Treatment per label instructions DANGER Fuel and vapors will be present during procedure whi...

Page 82: ... 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 operating conditions The EFI system is controlled b...

Page 83: ...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 84: ... from the engine or spilled during service Dispose of coolant and absorbent materials according to local environmental regulations WARNING Do not open the coolant filler cap when the engine is hot Steam or hot fluid could spray out causing severe burns CAUTION Ethylene glycol coolant is an eye irritant Wear eye protection when working with coolant If your engine is equipped with a freshwater cooli...

Page 85: ...nt 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 solution Run engine for 10 minutes to ensure proper mixing of solution and recheck for level of protection Repeat if necessary until ...

Page 86: ...haust manifolds M risers R elbows E and pipe P for signs of corrosion For replacement of exhaust parts see your Volvo Penta dealer Ignition System Maintenance for the ignition system is limited to cap and rotor inspections and replacing the spark plugs For more complex repairs see the Workshop Manual or your Volvo Penta dealer Firing order 1 6 5 4 3 2 NOTICE When replacing or installing spark plug...

Page 87: ...Spark Plugs Very high quality spark plugs were installed in your engine at the factory Replacement spark plugs must be of equal quality See your dealer for the correct 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 slight...

Page 88: ... 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 batteries with t...

Page 89: ...pening until oil is at proper level If level is too high remove 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 ot...

Page 90: ...e located at the leading edge of the lower unit provides pressure input for the speedometer If the pitot tube becomes clogged e g silt sand vege tation the speedometer may stop functioning There are two methods for clearing debris from the pitot tube Method 1 Use a six inch length of stiff wire of 1 8 in 3 mm thickness or a wire coat hanger to push any debris in the pitot tube into the drive cavit...

Page 91: ...purchased from your Volvo Penta dealer meet the highest specifications for material composition and purity Some aftermarket anodes may not meet these quality specifications 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 shi...

Page 92: ...oves whenever you remove or replace a propeller Do not attempt to hold propellers by hand when you remove or install propellers and propeller nuts Serious 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 provide...

Page 93: ...ller nut Remove the front propeller NOTICE If the propeller is stuck to the shaft lightly tap the forward edge of the propeller blades with a non metallic hammer If the propeller will not move contact your dealer 4 Clean the propeller shafts If reinstalling the propellers clean the hub splines Inspect for fishing line or other debris Remove if present Installation Before starting have the followin...

Page 94: ...797 and torque wrench 4 Install the rear propeller Install the rear propeller nut chamfered edge for ward 5 Torque nut to 70 Nm 50 ft lb Use torque wrench and 30mm socket 6 Remove the wood block Both propellers should turn freely For aluminum propellers if the propeller nuts are diffi cult to remove do not use the wood block to stop the propellers from turning Use the control mechanism to shift th...

Page 95: ...stallation Before starting have the following on hand new cotter pin propeller grease torque wrench 1 1 16 socket needle nose pliers NOTICE All propeller hardware must be installed according to the steps that follow Missing or improp erly installed hardware can lead to propeller loss or drive damage 1 Shift control in to reverse to keep the propeller from turning 2 Coat propeller shaft S and prop ...

Page 96: ...check the engine oil also check the steering reservoir fluid level The fluid level must be above the Min line and below the Max line If needed add Volvo Penta Power 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...

Page 97: ...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 98: ...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 79 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 99: ...y 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 shiel...

Page 100: ...0 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 minute reserve capacity STERNDRI...

Page 101: ...S RON 90 NOTICE Engine damage resulting from the use of lower octane gasoline below 87 AKI or 90 RON is considered misuse of the engine and is not covered by the warranty All Volvo Penta gasoline engines are engineered to operate on AKI 87 RON 90 octane fuel Mid grade and premium fuels contain injector cleaners and other additives that protect the fuel system and provide improved performance EFI e...

Page 102: ...reate problems in marine fuel systems It acts as a solvent and it attracts and holds water in a much higher per centage than non ethanol fuels Users of ethanol blended fuels must take additional care in the mainte nance of their fuel systems Ethanol blended fuels should not cause engine problems if the fuel and fuel system are properly maintained accorded to the instructions given in this manual S...

Page 103: ...olant types Do not use other coolant types such as traditional green ethylene glycol propy lene glycol pink OAT or HOAT coolants Volvo Penta offers ready to use pre mixed containers of the VCS coolant If using full strength antifreeze use a 50 50 mix of antifreeze and distilled water Also see below Checking Engine Coolant for Freeze Protec tion page 83 P0016256 Technical Data 47706041 07 2014 AB V...

Page 104: ...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 105: ...5 synthetic gearcase lubricant NOTICE Whenever you are changing or topping up the oil always check the oil level using the dipstick Sterndrive Oil Capacity All SX Models 2 8 quarts 2 7 liters All DPS Models 2 6 quarts 2 5 liters NOTICE If your drive is equipped with a Drive Spacer you will need to add more oil than the recommended amount P0016608 P0016609 Technical Data 47706041 07 2014 AB VOLVO P...

Page 106: ...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 107: ...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 108: ...ficate Number V6 200 149 kW EXVOL002 SDVOL009 V6 225 168 kW EXVOL002 SDVOL009 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex I B 4 Annex I C Noise Emissions Soun...

Page 109: ...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 47706041 07 2014 AB VOLVO PENTA 107 ...

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Page 111: ...water Cooling System 82 Friction Brake 20 Fuel System 76 99 Fuel Treatment During Storage 79 G Gauges 16 H High Altitude Operation 41 High Performance Boat Operation 41 Hot Water Outlet 22 Hour Meter 66 I Identification Numbers 104 Ignition Lock 15 Ignition switch 15 Ignition System 84 Impeller Checking Replacing 82 Inlet and Exhaust System 84 L Laying Up Winterization 95 Less than Optimal Perform...

Page 112: ...iliary Batteries 50 Static Water Line 62 Static Water Line Test 63 Steering 60 94 Steering System Operation 37 Stop the Engine 43 Stop the Engine Before Service 71 T Throttle Only 36 Trailering Your Boat 45 Trim Ranges 32 Trim Tilt Motor Protection 35 Twin Unit Steering 38 V Volvo Action Service VAS 13 Volvo Penta Dealer Network 14 Volvo Penta on the Internet 14 W Warranty Information 13 Water hea...

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Page 114: ...VPA 47706155 English 01 2015 VPA 47706041 English 07 2014 ...

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