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Volvo Penta 3.0GLP-J Operator's Manual

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OPERATOR'S MANUAL
3.0L, 4.3L, 5.0L, 5.7L, 8.1L
SX-A, DPS-A

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Summary of Contents for Volvo Penta 3.0GLP-J

  • Page 1 OPERATOR’S MANUAL 3.0L, 4.3L, 5.0L, 5.7L, 8.1L SX-A, DPS-A...
  • Page 2 Copyright © 2009 Volvo Penta of the Americas, Inc. All rights reserved. This publication may not be copied, photocopied, reproduced, or converted to any electronic or machine-readable form in whole or in part without the express written consent from...
  • Page 3 Content Foreword ...................... 2 Safety Information ..................4 Introduction ....................12 Instruments and Controls ................ 14 Optional ..................... 21 Starting ...................... 23 Operation ....................30 Engine Shutdown ..................45 In Case of Emergency ................51 Troubleshooting ..................53 Maintenance Schedule ................70 Maintenance ....................
  • Page 4 Foreword This manual applies to the following engines and sterndrives: Raw Water Cooled Engine Model Spec. No. Drive Displacement 3.0L 3.0GLP-J 3869388 SX-A 4.3GL-J 3869391 4.3L SX-A & DPS-A 4.3GXi-J 3869393 5.0GL-J 3869397 5.0L SX-A & DPS-A 5.0GXi-J 3869399 5.7Gi300-J 3869403 5.7L...
  • Page 5 Volvo Penta product. Volvo Penta continually commits a considerable part As an owner of a Volvo Penta marine engine, we of its development resources toward minimizing the would also like to welcome you to a worldwide net- environmental impact of its products.
  • Page 6 If you do not understand or are uncertain about any operation or information in this owner’s manual, please contact your Volvo Penta dealer. Your dealer will be able to help you with an explanation or will demonstrate the operation. Federal law requires manufacturers to notify owners in the event that a safety related defect is discovered on any of their products.
  • Page 7 Safety Information Maintenance Performing maintenance on the engine can be a dangerous undertaking. We strongly recommend that you con- sult your dealer. Find the correct information in the following publications: this operator’s manual, any applicable Do it Yourself manual, and any applicable workshop manuals. Engine Decals Check that the warning decals on the engine are always clearly visible.
  • Page 8 Safety Information Serpentine Belt and Pulley System CAUTION! Working around the serpentine belt and pulley system can be dangerous. To prevent possible injury caused by pinching, crushing or entanglement, always observe these precautionary measure when working around the engine: ● Ensure that the engine cannot be started by removing the ignition keys from each starting location. This hazard is especially likely to occur if the engine room or engine compartment cannot be seen from various remote starting positions such as a flybridge or enclosed cabin.
  • Page 9 Safety Information Carbon Monoxide DANGER! Do not run the engine while there are people located on or near the swim platform and transom. DANGER! Do not tow anyone using water sports equipment (such as skis and inner tubes) closer than twenty feet (6 meters) from the boat.
  • Page 10 Safety Information How is a Person Affected by Carbon Monoxide? Carbon monoxide is absorbed by the lungs and reacts with blood hemoglobin to form carboxyhemoglobin, which reduces the oxygen carrying capacity of the blood. The result is a lack of oxygen for the tissues, with subsequent tissue death and, if exposure is prolonged, death of the individual.
  • Page 11 Safety Information Stationary Operation A boat operator should be aware that dangerous con- centrations of CO can accumulate when propulsion engines and/or an auxiliary generator is operated while the boat is stationary. This is especially true when rafted or moored in a confined area such as boat- houses, or when in close proximity to seawalls or other boats.
  • Page 12 Safety Information Underway Operation Do not sit on, occupy or hang on any stern appendages (e.g., swim platforms, boarding ladders, etc.) while underway. Do not body surf, commonly known as “teak surfing” or “platform dragging,” in the wake of the boat. Do not tow persons in close proximity to the stern of the boat.
  • Page 13 Refer to the Maintenance Schedule and Main- tenance sections of this manual for instructions on keeping your engine and sterndrive in good condition. NOTICE! Be sure to see your Volvo Penta dealer for regular inspections. 47700385 05-2009...
  • Page 14 Penta. Your dealer should provide you with proof of ownership in the form of an Owner's Registration Card or a print-out of the Volvo Penta computer on-line reg- istration screen. This provides proof of ownership and is required to validate warranty, should warranty serv- ice become necessary.
  • Page 15 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 company and all the new and innovative products we have to offer.
  • Page 16 Instrument panels can also be supplemented with extra Volvo Penta instruments such as: synchronization tach- ometers, fuel gauge, fresh water gauge, clock, speedometer, or rudder indicator.
  • Page 17 Instruments and Controls Volvo Penta ignition keys are marked with a code for use when ordering extra keys. Record the code so that replacement keys can be ordered. Keep the code in a safe place where unauthorized persons do not have access to it.
  • Page 18 Instruments and Controls Power Trim Buttons The buttons on the power trim control panel are used for both single and twin engine installations. For twin engine installations, the power trim control panel can be used to make individual or simultaneous adjustments to the drives.
  • Page 19 Instruments and Controls Trim Ranges In order to utilize the information gained from the trim instrument, it is essential to know about the different trim ranges and their uses. There are three trim ranges as described below. Trim Range Trim range, for a drive with a single prop, is any angle between -5°...
  • Page 20 Instruments and Controls Power Trim Instrument and Displays Digital Instrument The digital instrument A shows the trim angle in digits and the trim range (TRIM) and beach range (BEACH) in letters. For an explanation of trim ranges, please refer to Trim Ranges in the previous section.
  • Page 21 Your boat may be equipped with remote controls other than those described below. If Volvo Penta controls are not used, ask your dealer for operating instructions for the remote control used in your boat since operation and function may differ from Volvo Penta remote controls.
  • Page 22 Generally, the remote control has a friction brake, which can be adjusted as necessary, to provide lighter or heavier lever action. If you are using a Volvo Penta shift control and you wish to make adjustments to the friction brake, follow the instructions below to make the necessary changes.
  • Page 23 Active Corrosion Protection System Your boat may be equipped with a Volvo Penta active corrosion protection system (APCS). This system operates with very little current drain from the boat’s electrical system. It keeps the voltage potential in the area around the drive unit in a range that is not corrosive to aluminum.
  • Page 24 ● Broken anode or reference sensor unit. Replace damaged unit. Follow the installation instructions included with the replacement unit, or see your authorized Volvo Penta dealer for service. If any of the malfunction conditions continue to exist after completing the steps above, see your authorized Volvo Penta dealer for further service.
  • Page 25 Starting Static Water Line Static water line is a measurement of the water level in the boat engine's exhaust system. The exhaust pas- sages of a sterndrive propulsion system are open to the water surrounding the boat A. When the engine is not running, the water level in the exhaust system will settle at the same level as the surrounding water B.
  • Page 26 3. Bring plugged end of hose inside the hull C 6. If the static water line does not meet these and hold next to–and above–the manifold B. specifications, contact your Volvo Penta dealer for information on high rise extension kits. Make sure one is installed before the engine is started for the first time.
  • Page 27 Starting Before Starting Before you attempt to start your engine, be sure to perform the inspection items provided in the daily checklist located in the chapter entitled Maintenance Schedule. WARNING! To prevent a possible explosion hazard, operate the engine compartment bilge blower as recommended by the boat manufacturer before starting the engine.
  • Page 28 Starting 3. Check the bilge for excessive water accumula- tion. Always keep the bilge clean and dry. NOTICE! The water level in the boat’s bilge will increase when you operate your boat at a high incline before you reach planing speed. Exces- sive water in the bilge can cause engine dam- age.
  • Page 29 21183–1 authorized Volvo Penta dealer for service. 2 . While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an audible alarm available, we strongly recom- mend that you contact your dealer to have one installed.
  • Page 30 Starting Fuel Injected Models 1. Move the control handle to the NEUTRAL detent position. 2. Turn the ignition switch to START II and hold, for no longer than ten seconds or until engine starts. If the engine does not start, let go momentarily, then try again.
  • Page 31 Starting Flooded Engine GL Models To clear a flooded engine: 1. Disengage the shift mechanism by pressing gear shift release A. 2. Move the remote control lever to FULL THROT- TLE B. 3. Turn the key switch to START II. 4.
  • Page 32 Volvo Penta. If you have non Volvo Penta equipment installed on your boat or if the Volvo Penta equipment installed is not covered in this manual, please refer to any additional documentation that came with your boat.
  • Page 33 For a detailed explanation of the problems mentioned above and the steps to take to deal with them, please refer to the chapter entitled Troubleshooting. 3 . While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an audible alarm available, we strongly recom- mend that you contact your dealer to have one installed.
  • Page 34 Operation Maneuvering Power Trim/Tilt Your Volvo Penta sterndrive is equipped with a power trim/tilt system as standard equipment. The power trim/tilt allows you to change the angle of the drive unit from the helm. Changing the angle of the drive unit in relation to the boat bottom is called trimming.
  • Page 35 Operation Operating Trim Controls Control Lever The control button on the control lever has two func- tions: ● Pressing the top half of the button moves the drive trim out while raising the boat’s bow. ● Pressing the bottom half of the button moves the drive trim in while lowering the boat’s bow.
  • Page 36 Operation Determining the Proper Trim The effect of the maximum “bow-up” and “bow-down” positions will be similar for most boats. The bow posi- tion best for your operating conditions could be at any trim setting between the maximum “bow-up” and “bow- down”...
  • Page 37 “bow-up” or “bow-down” positions. Boat stability and steering torque can also vary due to changing water conditions. If you experience boat instability and/or high steering torque, see your Volvo Penta dealer to correct these conditions. 47700385 05-2009...
  • Page 38 If there is damage, operate the boat at low RPM and 50406 take it to a Volvo Penta dealer for inspection. Operating a damaged unit could cause additional damage and could become very costly to repair. Have necessary repairs made immediately. Only operate your boat if absolutely necessary.
  • Page 39 Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncom- fortable. Volvo Penta recommends a cruising speed 25% lower than maximum RPM at WOT. Depending on hull type, choice of propeller, load and conditions, etc., the maximum engine speed at top speed can vary, but it should be within the WOT range.
  • Page 40 If you suspect there is a problem, see your Volvo Penta dealer as soon as possible for proper diagnosis and required service or adjustment. Continued operation...
  • Page 41 Operation Twin Unit Maneuvering When leaving or approaching the dock, or for any close maneuvering at slow speed, place the port engine con- trol lever 3 in neutral N (on standby) and use the star- board engine. The use of one control is very effective and more convenient.
  • Page 42 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.
  • Page 43 Operation Steering with Control Levers Rotating the Boat Move one control lever into forward gear and the other control lever into reverse gear. Use a suitable engine speed for maneuvering. The direction of rotation is determined by the lever which is moved into reverse.
  • Page 44 ● Boats with sensitive steering ● Boats where the distance from the top of the gunwale down to the driver’s seat is less than one foot (30 cm). Contact your Volvo Penta dealer for installation of an emergency stop switch. 47700385 05-2009...
  • Page 45 NOTICE! Freeze damage to the engine package is not covered by your Volvo Penta limited warranty. Upon completion of engine operation, drain the engine as described below: 21199 ●...
  • Page 46 Volvo Penta Limited Warranty. 22799 Salt Water Operation You can use your Volvo Penta sterndrive in either fresh or salt water. We recommend that you use fresh water to flush out the engine and drive after you use your boat in polluted or salt water.
  • Page 47 Engine Shutdown Before Engine Shutdown WARNING! Never abruptly change speed. Sudden changes in speed may cause passengers to be thrown about in the boat. Power Tilt Operation Tilting is normally used for raising the drive unit to obtain clearance when beaching or launching from a trailer.
  • Page 48 Engine Shutdown Engine Flush Volvo Penta engines incorporate an engine flushing port designed to flush the engine with fresh water while the engine is running. Flushing the engine with fresh water after each use will increase the longevity of com- ponents.
  • Page 49 Engine Shutdown Trailering Your Boat 1. Before loading your boat on the trailer, tilt the drive unit up. 2. After your boat is on the trailer, completely lower the drive unit until the drive drains thoroughly. 3. Rinse the entire drive exterior with fresh water. NOTICE! Before moving the trailer, tilt the drive as high as possible and secure it in place.
  • Page 50 Engine Shutdown Draining the Engine Draining 3.0L Engines 1. With the engine turned off, locate and open all drain points. Raw water drains are blue, hardened plastic plugs. NOTICE! Be sure that all water is drained from the engine. If no water drains, use a piece of wire to clear any obstructions from the drain holes.
  • Page 51 Engine Shutdown Draining Raw Water Cooled Engines 1. With the engine turned off, locate and open all drains located on both sides of the engine. Raw water drains are blue, hardened plastic plugs. NOTICE! Be sure that all water is drained from the engine.
  • Page 52 Engine Shutdown Draining Raw Water Side of Closed Cooling System Engines 1. With the engine turned off, locate and open all drains located on the manifolds on both sides of the engine. Do not drain engine block! NOTICE! Be sure that all water is drained from the manifolds.
  • Page 53 Lift the boat ashore. Check the drive oil level and qual- ity. If the oil is milky-white, water has entered the drive and it must be inspected by an authorized Volvo Penta workshop. Replace the propeller if it is damaged.
  • Page 54 In Case of Emergency Starting Using Auxiliary Batteries DANGER! Never allow an open flame or electric sparks near the battery or batteries. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which, when mixed with air, can form an explosive gas.
  • Page 55 ● Did the trouble occur suddenly or did it become apparent gradually? Whether servicing the boat’s systems yourself or having your product serviced by a certified Volvo Penta dealer, you will need this record of information to identify potential causes of the malfunction.
  • Page 56 ● Secondary circuit wiring, from coil to spark plug. ● Spark plugs–for proper gap, fouling, burned electrodes, or cracked/dirty insulator. ● Low battery voltage. ● Call for assistance or see Volvo Penta authorized dealer. Fuel System – Check: ● Fuel level.
  • Page 57 ● Fuel pump pressure. ● Water or contaminants in fuel. ● Manifold vacuum leak. ● Call for assistance or see Volvo Penta authorized dealer. If At High Speed – Check: ● Air leak on suction side of fuel system. ● Too low octane fuel.
  • Page 58 ● 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 the section entitled Engine Protection Mode.
  • Page 59 To Prevent: ● All electrical accessories including ignition circuit are turned off. ● Turn battery switch off and disconnect main battery negative cable from battery. ● If problem persists, call for assistance or see Volvo Penta authorized dealer. 47700385 05-2009...
  • Page 60 A great number of environmental factors, such as baro- metric pressure, ambient temperature, humidity, the quality of fuel, and exhaust back pressure can affect engine performance. All Volvo Penta engines are tested and certified using the following fixed values or common conditions for determining the rating of the engine.
  • Page 61 If the problem continues, contact your Volvo Penta dealer and have the engine inspected. 4 . While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an audible alarm available, we strongly recom- mend that you contact your dealer to have one installed.
  • Page 62 See the next section for additional infor- mation. If the problem persists, contact your Volvo Penta dealer and have the engine inspected. 47700385 05-2009...
  • Page 63 NOTICE! Ignoring an overheating situation can cause engine damage and/or equipment failure which may not be covered by your warranty. If the situation persists, contact your Volvo Penta dealer for assistance. Engine Overheating (Carbureted) NOTICE! Carbureted engines are not protected against overheating! If the engine overheats, you must take action to protect your engine.
  • Page 64 Troubleshooting Water in Bellows OceanX (OXi) drives are equipped with a sensor that detects water intrusion in the bellows. If water is detected inside the bellows, an alarm horn will sound for one second every sixty seconds. If this alarm sounds, please contact your dealer for repairs as soon as possible.
  • Page 65 If a pump does not function, check the fuses and replace them if necessary. See your Volvo Penta dealer if further service is required. 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.
  • Page 66 ● Replace any blown fuses. NOTICE! Circuit breakers or fuses that repeatedly fail indicate a problem that requires immediate attention. See your Volvo Penta dealer. Fuse and Relay Box Layout Several spare fuses and relays are located on the inside of the fuse and relay box cover. In case of malfunctioning or faulty fuses and relays, use the spares provided.
  • Page 67 Troubleshooting 4.3GXi-J, 5.0GXi-J(F), 5.7Gi300-J(F), 5.7GXi-J(F), 8.1Gi-J(F), 8.1GXi-J(F) Trim Down Relay 20 Amp Fuse (Fuel Pump) Trim Up Relay 15 Amp Fuse (Ignition) Starter Relay 5 Amp Fuse (Vessel Switch) Fuel Pump Relay 20 Amp Fuse (ECM) Ignition Relay 40 Amp Fuse (Instrument Panel) 15 Amp Fuse (Diagnostic Connector) 40 Amp Circuit Breaker (Trim Pump) 10 Amp Fuse (Trim Control)
  • Page 68 2. Make sure remote control is in NEUTRAL. 3. Coat full length of prop shaft and inside of prop hub with Volvo Penta prop shaft grease; removal of prop will be difficult if this is not done. 4. Ensure thrust bushing 1 is on prop shaft with inner taper toward gearcase to match taper on prop shaft.
  • Page 69 Troubleshooting Removing the DPS-A Propeller NOTICE! This “get home” (emergency) procedure This procedure requires you to use Volvo Penta spe- will require you to have tools and spare prop(s) cial tools. and nuts on hand. 1. Turn ignition switch to RUN I (key on, engine off).
  • Page 70 Engine Submersion 1. Remove the engine from the water as quickly as possible. 2. Contact your local Volvo Penta dealer for service. ● Your dealer will need to drain all water from the engine and immediately lubricate all internal parts.
  • Page 71 Troubleshooting Steering If you experience difficulty steering the boat, check for the following possible problems: ● Check the fluid level in the power steering pump reservoir. The level must be between the “Min” and “Max” lines. ● Check that all hose clamps on the power steering system are securely tightened.
  • Page 72 Please see the checklists and maintenance schedules in this chapter. The operation, maintenance, and care of the Volvo Penta engine and power package, as outlined in this manual, are an owner's responsibility. The owner must keep records of all maintenance and service performed. This record of proper maintenance may be required to determine warranty coverage.
  • Page 73 Maintenance Schedule Owner's Checklist Check/ Fill/ Adjust/ Change/ Check Before Each Use Clean Correct Lube Tighten Replace Engine Cooling System – Check coolant level ; check ● ● system for leaks Engine Oil ● ● Fuel Pump and System – Check for leaks ●...
  • Page 74 See Technical Data. In markets outside the United States: All service specified by the maintenance schedules for the first year must be performed and documented by an authorized Volvo Penta dealer to be eligible for the Extended Pro- tection Service Plan.
  • Page 75 4) Engine oil change interval can be increased to 200 hours if full synthetic oil is used, see Scheduled Oil Service in the chapter entitled Technical Data. 5) Fresh water cooled versions. 6) Must use genuine Volvo Penta parts for 3 year change; change is every year for other plugs. 47700385 05-2009...
  • Page 76 Maintenance Schedule Annual Service or Every 100 Hours Check/ Fill/ Adjust/ Change/ Clean (Continued) Correct Lube Tighten Replace Sterndrive Anodes – Visual inspection; replace if eroded more ● than 30% Bellows, U-joint, and Exhaust – Check for wear, ● ● damage;...
  • Page 77 If you are uncertain about any procedures described in the manual or you would like to purchase a workshop or Do it Yourself manual, please contact your Volvo Penta dealer or visit Volvo Penta on the Internet. Keep in mind, however, that there are certain tasks which should only be performed by your Volvo Penta dealer.
  • Page 78 We recommend that all servicing with the engine running be undertaken by an authorized Volvo Penta workshop. Starting the Engine After Service Reinstall all protective parts removed during service operations before starting the engine.
  • Page 79 Maintenance Batteries Incorrect connection of the battery can cause a spark, which would be sufficient to cause an explosion. Do not disturb battery connections when starting the engine (spark risk) and do not lean over batteries. Always ensure that the positive and negative battery leads are correctly installed on the corresponding ter- minal posts.
  • Page 80 Otherwise the general instructions contained in this Operator’s Manual concerning operation, service, and main- tenance must be followed. NOTICE! Late or inadequate maintenance/service or the use of spare parts other than Volvo Penta original spare parts will invalidate Volvo Penta’s responsibility for the engine specification being in accordance with the certified variant.
  • Page 81 ● Exposed cords or excessive fraying ● Oil or grease 51535 If you suspect the belt needs replacing, please refer to the Do it Yourself manual for the procedure or take your boat to a Volvo Penta dealer. 47700385 05-2009...
  • Page 82 Engine Alignment Because of the special tools required, a Volvo Penta dealer must do the engine alignment. This should be done during off-season storage preparations.
  • Page 83 Maintenance Fuel System Fuel Screen Replacement (3.0 Liter Carb Engines) Before you begin this procedure, be sure you have the following on hand: ● Ceramic screen and gasket ● Wrench ● Screwdriver ● Container and absorbant rags for catching fuel spills 1.
  • Page 84 Maintenance Fuel Filter Replacement (V6/V8 Carb Engines) Before you begin this procedure, be sure you have the following on hand: ● Fuel Filter ● Oil ● Wrench ● Container and absorbant rags for catching fuel spills 1. If possible, remove all passengers from the boat. If this is not feasible, ensure that all passengers are above-decks and away from confined com- partments.
  • Page 85 Maintenance Engine Fuel Filter Replacement Before you begin this procedure, be sure you have the following on hand: ● Fuel Filter ● Wrench ● Oil ● Container and absorbant rags for catching fuel spills 1. If possible, remove all passengers from the boat. If this is not feasible, ensure that all passengers are above-decks and away from confined com- partments.
  • Page 86 Maintenance Cooling System NOTICE! Do not run the engine without the thermostat as the engine is likely to overheat. Replacing the Engine Thermostat 3.0 Liter Engines 1. Loosen hose clamp 2. 2. Remove hose 1 from thermostat housing 5. 3. Remove O-ring 3 and thermostat 4 from housing. Discard thermostat.
  • Page 87 Replace as necessary. 4. Lubricate the pump housing with non-petroleum based lubricant, suitable for rubber, such as glyc- erine. If you have purchased the Volvo Penta impeller kit, a packet of glycerine is included. 5. Reinstall the impeller. Reinstall the housing.
  • Page 88 Maintenance Electrical System Battery Maintenance and Replacement DANGER! Never allow an open flame or electric sparks near the battery or batteries. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which, when mixed with air, can form an explosive gas.
  • Page 89 Maintenance Spark Plugs Your engine comes equipped with high quality spark plugs that require infrequent maintenance. Please see Maintenance Schedule for replacement frequency. WARNING! 23172-e Ensure that plug wires are in good condition to avoid sparking. Sparking could potentially cause a fire or explosion.
  • Page 90 No regular oil level check is required unless trim system performance is poor. If system performance is poor, refer to the Do it Your- self manual or consult your Volvo Penta dealer. 50408 47700385 05-2009...
  • Page 91 Maintenance Pitot Tube (Speedometer Port) The pitot tube, located at the leading edge of the lower unit, provides pressure input for the speedometer. If the pitot tube becomes clogged (e.g. the boat runs aground or the sterndrive drags through silt as the boat is loaded onto the trailer), the speedometer may stop functioning.
  • Page 92 Follow equipment manufacturers rec- ommendations. Anode Replacement Information NOTICE! Your Volvo Penta product has been shipped with Aluminum anodes. The table below provides replace- ment information and also specifies which anodes should be used, depending on water conditions. Anode Material Part No.
  • Page 93 Painting the Drive The sterndrive and transom shield require a unique paint repair procedure. Please refer to the Do it Your- self manual or see your Volvo Penta dealer for addi- tional information regarding painting the drive. Anti-fouling Paint: Drive and Transom...
  • Page 94 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.
  • Page 95 Storage Laying Up (Winterization) Be sure that your Volvo Penta equipment is properly prepared for long or short term storage. Engine or drive damage can result if some simple maintenance steps are overlooked prior to storage. Winterizing gives you the assurance that your engine will be protected during storage and will run more reliably when you put your boat back in the water.
  • Page 96 Storage Long Term Storage More than two months: Fuel stabilizer (1 oz per gallon of fuel). Fuel and 2-cycle motor oil mixture, 50:1 ratio (one pint to 6 gallons). Fog engine (carburetted only). Replace engine oil and oil filter. Replace sterndrive oil. Flush engine with fresh water.
  • Page 97 Storage Bringing Out of Storage When launching your boat for the first time or when starting out a new season, always carry out the steps provided in the following checklist: Reinstall all engine drain plugs. Reconnect any hoses removed for storage. Check condition of hoses;...
  • Page 98 Technical Data Engines Disclaimer Volvo Penta of the Americas, Inc., reserves the right to make changes in weight, construction, materials, or specifications without notice or obli- gation. 47700385 05-2009...
  • Page 99 160°F (71°C) OIL FILTER Engine oil filter ... . . Volvo Penta, spin-on can OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 100 150°F (66°C) OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 101 150°F (66°C) OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 102 Ethylene glycol OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 103 Ethylene glycol OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 104 Ethylene glycol OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 105 Ethylene glycol OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 106 Ethylene glycol OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 107 Ethylene glycol OIL FILTER Engine oil filter ... . . Volvo Penta, replaceable paper element OIL CAPACITY NOTICE! Overfilling the oil can cause engine and/or sterndrive damage. We urge you to use the dipstick to check the oil level whenever you are changing or topping up the oil.
  • Page 108 The oils are available at Volvo Penta dealers. If the Volvo Penta oils are not available, use a high quality oil that meets API SM and/or ILSAC GF-4 specifications. Viscosity should be SAE 10W30 or higher (examples;...
  • Page 109 Maintain oil level between E (add) and D (full) on the dipstick. If oil is added, use an approved Volvo Penta oil for gasoline engines; if unavailable, use a high quality oil that meets the Engine Oil Specifications.
  • Page 110 22823 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.
  • Page 111 Volvo Penta gasoline engines are equipped with a water separating fuel filter (see Engine Fuel Filter Replacement in the section entitled Maintenance). The use of an additional water separating fuel filter between the fuel tank and the engine is recommended.
  • Page 112 The EFI system is controlled by a microprocessor, and requires no periodic mainte- nance or adjustment. If operational problems occur, see your Volvo Penta dealer. Detonation (Spark Knock) Detonation, or spark knock, is continually monitored by the electronic fuel injection (EFI) system. The EFI’s...
  • Page 113 Technical Data Electrical System Battery Cables When replacing battery cables, always use multi- strand copper cables of the same gauge (or better) as those already installed in your boat by the boat builder. If you are unsure of the gauge to be used, consult your dealer.
  • Page 114 Technical Data Sterndrive Drive Components The drive unit is filled at the factory with Volvo Penta Synthetic Gear Oil. Change lubricant as specified in Maintenance Schedule. Use Volvo Penta SAE 75W/90 API service GL 5 synthetic gearcase lubricant. Sterndrive Oil Capacity All SX-A Models: 2.58 quarts (2.44 liters)
  • Page 115 Technical Data Identification Numbers Informational Decals and Identification Plates The following images provide graphical representations of various engine decals. The areas described are gen- eral locations and are intended to be guides only. Engine models and configurations do vary and, depending on the amount of space available, the exact locations of engine decals tend to vary also.
  • Page 116 Technical Data The Emission Control Information sticker is located on the flat outside face (port side of engine) of the alternator support bracket. 22776 The tune-up and color code decal is located on the engine cover. 22775 47700385 05-2009...
  • Page 117 Technical Data Identification Numbers Always provide the engine, transom shield, and drive identification numbers when ordering service or replace- ment components. The engine identification numbers are on informational decals located in the spots described on the previous page. Make a note of the information on the lines provided below. Make a copy of this page and store the information so that it is available in event of the boat being stolen.
  • Page 118 Technical Data Declaration of Conformity Recreational Craft Propulsion Engines Declaration of Conformity for Recreational Craft Pro- pulsion Engines with the sound and exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC 47700385 05-2009...
  • Page 119 Technical Data 3.0 Litre Engine Manufacturer: Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé Cuypres 3, B-1040 Bruxells, Belgium Rue Abbé...
  • Page 120 Technical Data 4.3 Litre Engine Manufacturer: Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé Cuypres 3, B-1040 Bruxells, Belgium Rue Abbé...
  • Page 121 Technical Data 5.0 Litre Engine Manufacturer: Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé Cuypres 3, B-1040 Bruxells, Belgium Rue Abbé...
  • Page 122 Technical Data 5.7 Litre Engine Manufacturer: Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé Cuypres 3, B-1040 Bruxells, Belgium Rue Abbé...
  • Page 123 Technical Data 8.1 Litre Engine Manufacturer: Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé Cuypres 3, B-1040 Bruxells, Belgium Rue Abbé...
  • Page 125 Alphabetical index Engine, General............79 3.0 Litre..............117 Engines..............96 4.3 Litre..............118 Flooded Engine............. 29 4.3GL Draining Only..........48 Friction Brake............20 5.0 Litre..............119 Fuel Filter Replacement (V6/V8 Carb Engines)..82 5.0GL-J, 5.0GL-JF..........100 Fuel Screen Replacement (3.0 Liter Carb 5.0GXi-J, 5.0GXi-JF..........
  • Page 126 Twin Unit Maneuvering..........39 Twin Unit Steering........... 40 Warranty Information..........12 Washing the Engine..........78 Water in Bellows............62 Water in Oil and Oil Level........62 Volvo Action Service (VAS)........12 Volvo Penta Dealer Network........13 Volvo Penta on the Internet........13...
  • Page 127 NOTE: This free-of-charge Operator’s Manual offer is valid for 12 months after engine delivery. Fill in your name, postal address, email address and desired language. Publication Reference: 47700385 Name: Address: Country: E-mail: English Dansk Svenska Soumi Deutsch Português Français Ελληνικά Español Русско...

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