1. Manuals
  2. Brands
  3. Volvo Penta Manuals
  4. Engine
  5. 5.0 GL
  6. Manual

Volvo Penta 5.0 GL Manual

Hide thumbs Also See for 5.0 GL:
Table of Contents

Advertisement

Quick Links

Workshop Manual
C
Engine
2(0)
5.0 GL
5.7 Gi
5.0/5.7 GXi
5.0/5.7 OSi, 5.7 OSXi

Advertisement

Table of Contents
loading

Related Manuals for Volvo Penta 5.0 GL

Summary of Contents for Volvo Penta 5.0 GL

  • Page 1 Workshop Manual Engine 2(0) 5.0 GL 5.7 Gi 5.0/5.7 GXi 5.0/5.7 OSi, 5.7 OSXi...
  • Page 2 Copyright © 2007 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 Volvo Penta of the Americas, Inc.
  • Page 3 Model Identification ....1 General Information ....3 Engine —...
  • Page 4 Notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 5 Volvo Penta engines, transmissions, transom shields, and drives. All sterndrive system components must be matched for either single or dual engine installations. Failure to properly match engine, transmission, transom shield, and drive unit will result in poor boat performance, and risk damage to engine and drive because of incorrect drive gear ratio.
  • Page 6 Model Identification 50328 The XP transom shield identification plate is located on the inner transom plate, above the steering ram. 50315 PROD. TYPE SER. NO. The identification plate for the SX-A/DPS-A stern- drives is located on the rear of the upper gear, just above the parting line between the upper and lower gear housing.

  • Page 7: Table Of Contents

    General Information General Information Tuning the Engine ........5 Intake Manifold Vacuum Testing .
  • Page 8 Service Policy It is a Volvo Penta policy to provide dealers with service knowledge so they can give professional service demanded by today’s consum- er. The Volvo Penta Training Centers, frequent mailing of Service...

  • Page 9: Tuning The Engine

    General Information Special Service Tools Volvo Penta has specially designed tools to simplify some of the dis- assembly and assembly operations. These tools are illustrated in this Service Manual, in many cases in actual use. All special tools can be ordered from Volvo Penta Parts. Individual purchasers of Service Manuals must order Special Tools through an authorized dealer.
  • Page 10 General Information Visually inspect stern drive unit for leaks, missing parts or other obvious defects. Replace deteriorated parts. Compression check: Proper compression is essential for good engine performance. An engine with low or uneven compres- sion cannot be properly tuned. •...
  • Page 11 General Information pressures. The chart has been calculated so that the lowest reading number is 75% of the highest reading. Compression Pressure Limit in PSI Max. Min. Max. Min. Max. Min. Max. Min. After checking cylinder compression, repairs should be made as necessary.

  • Page 12: Intake Manifold Vacuum Testing

    Repair or replace components only as required. WARNING! Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine com- partment.
  • Page 13 General Information See table and chart below and on the following page for more information. Vacuum Gauge Readings Condition Reading Normal at Idle 14-19 in. Hg. (47-64 kPa) Late Ignition Timing 11-17 in. Hg. (37-57 kPa) Late Valve Timing 8-15 in. Hg. (27-50 kPa). Intake Leak Low but steady reading Normal Acceleration...

  • Page 14: Gasoline Requirements

    86 AKI (89 RON) and lower is considered misuse of the engine and will void the engine warran- ty. Volvo Penta suggests the use of 89 AKI or higher fuels. These fuels have additives that are beneficial to maximum engine performance and long life of service components.

  • Page 15: Gasoline Containing Alcohol

    NOTICE! The use of multi-viscosity oils, such as 10W-30 or 10W-40, is allowed but not recommended. Draining and Filling the Engine Crankcase If using Volvo Penta Premium Synthetic Engine Oil, drain and refill crankcase every 200 hours of operation or once a year, whichever occurs first.
  • Page 16 General Information Check the motor oil level frequently with the dipstick. When oil is to be changed, remove dipstick and withdraw oil from crankcase through withdrawal/dipstick tube. The oil withdrawal tube is provided so oil does not have to be drained into the bilge. Withdraw oil with a suction pump.

  • Page 17: Oil Filter

    18 ft. lb. (24 Nm) Power Steering Maintain the level with Volvo Penta Power Trim/Tilt & Steering Fluid. Approved power steering fluids such as GM power steering fluid or Dexron II automatic transmission fluid can also be used. Do not over- fill the pump reservoir.

  • Page 18: Off-Season Storage

    General Information Boat manufacturers should follow the gasoline storage mixture sec- tion for testing prior to shipment. Fuel stabilizer can be purchased lo- cally at most marine supply stores. Limited Use If the vessels fuel within the tank(s) will not be consumed within a 30- day period from the time of filling, a gasoline fuel stabilizer must be added as per the manufacturer’s instructions.
  • Page 19 Improper or incomplete draining may result in freeze damage to the engine, manifolds, sterndrive, or other components. Freeze damage is not covered under Volvo Penta’s Limited Warranty. Front Disable ignition system See Engine Compression Testing on page 5.

  • Page 20: Preparation For Boating After Storage

    General Information Reconnect ignition system. Starboard Disconnect and drain large hose at circulation pump Port Remove exhaust manifold drain plug. Clear hole with a small wire to ensure complete drainage. Remove cap from engine flush hose and lower hose into bilge. Preparation for Boating After Storage Install all drain plugs.

  • Page 21: Engine Break-In

    General Information quently to be sure all systems are operating properly. Check for fuel, oil, and water leaks. Engine Break-in All engines have been run for a short period of time as a final test at the factory. You must follow the Engine Break-In procedure during the first 20 hours of operation to ensure maximum performance and longest engine life.

  • Page 22: Submerged Engine Or Water Ingestion In Cylinders

    General Information Watch oil pressure gauge. If gauge indication drops below the normal operating oil pressure range (See Engine Specifications in the back of this manual.) whenever boat attitude is changed (i.e. turning, climbing on plane, etc.), it may be the oil pickup screen is not covered with oil.

  • Page 23: 20-Hour Check

    Check flame arrestor for proper mounting. Start engine and check complete fuel system for leaks. Lubricate steering cable ram with Volvo Penta grease P/N 828250. Check power steering pump reservoir for correct fluid level on models equipped with power steering. Failure to prop- erly lubricate the steering system could lead to loss of steering control.

  • Page 24: Positive Closed Ventilation System

    General Information whether loping or rough idle condition is caused by a malfunctioning crankcase ventilation system, perform the following tests. With Engine Idling Remove PCV valve from its mounting, but leave vacuum inlet side connected to hose. If the valve is functioning properly and not plugged, a hissing noise will be heard as air passes through valve.

  • Page 25: Troubleshooting - System Isolation

    General Information malfunction, refer to the individual system troubleshooting charts to isolate the specific cause. System Isolation Engine Does not Start Engine should crank at specified RPM. If not, check for Discharged or dead Battery Cranking System Loose or corroded connections Cranking System Troubleshooting Chart in the Elec- trical Ignition/ Fuel Service Manual Ignition System...

  • Page 26: Engine Troubleshooting Guides

    General Information tion. Start gathering information from the boat operator and write it on his job card or work ticket. Find out pertinent facts, such as: • When did this trouble start? • How was the boat loaded? • Did the trouble occur suddenly, or start gradually? Analyze this information and try to match it to similar situations you have experienced in the past.

  • Page 27: Engine Will Not Crank

    General Information • Primary circuit wiring from ignition switch to ignition coil/igni- tion module • Secondary circuit wiring from coil to spark plug • Spark plugs for proper gap, fouling, burned electrodes, cracked or dirty insulator • See Electrical/Ignition/Fuel Service Manual •...

  • Page 28: Hard Starting - Cold Engine

    General Information See Electrical/Ignition/Fuel System Service Manual Is This A New Condition? Check: Carburetor choke operation and adjustment Carburetor accelerator pump Fuel system for leaks, dirt, or obstructions Engine timing and ignition system See Electrical/Ignition/Fuel System Service Manual Hard Starting - Hot Engine Ask these questions first: Has Engine Always Done This? Check:...

  • Page 29: Engine Noises And Vibrations

    General Information Internal carburetor fuel leak See Electrical/Ignition/Fuel System Service Manual If At High Speed Check: Air leak on suction side of fuel system Too low octane fuel Ignition system secondary circuit Engine timing Wrong model or size carburetor, improper main jets or power valve, defective secondary fuel circuit, secondary vacuum dia- phragm failure External canister and carburetor fuel filters...

  • Page 30: Engine Overheats - Check

    General Information Crankshaft Balancer or Flywheel Loose bolt(s) Alternator Loose pulley, worn bearings Loose mounting bolts Sterndrive Failed U-joints or gimbal bearing Damaged internal drive components Worn, bent or broken propeller hub or blades Loose, worn or damaged engine coupler Engine Overheats Check: Actual engine temperature by verifying with an accurate ther-...

  • Page 31: Defective Engine Lubricating System

    General Information Carburetor cleanliness and operation See Electrical/Ignition/Fuel System Service Manual Loss Of Ignition Check: Primary and secondary ignition circuits Ignition switch Circuit breakers Wiring between engine and dash Main engine harness wiring See Electrical/Ignition/Fuel Service Manual Engine Stops Or Dies Out Due To Seizure Check: Vertical drive for internal damage Oil pressure gauge and crankcase oil level...

  • Page 32: Low Battery Voltage After Short Storage

    General Information Worn or collapsed oil pump relief valve spring, or foreign mate- rial caught on valve seat Oil pump relief valve plunger loose in cover Damaged filter bypass grommet Clogged oil pickup screen, broken tube or housing Plugged crankshaft or blocked oil galleys Dirty or defective hydraulic lifters, clogged push rod passages Poor quality, incorrect viscosity or quantity of oil Oil level too high - too much oil in the crankcase...
  • Page 33 Engine — 5.0 & 5.7 Litre Engine — 5.0 & 5.7 Litre General Description........30 Tools and Shop Equipment .

  • Page 34: General Description

    Engine — 5.0 & 5.7 Litre GL..........85 Water Pump Installation.

  • Page 35: Tools And Shop Equipment

    Engine — 5.0 & 5.7 Litre Camshaft A steel camshaft is supported by five bearings pressed into the en- gine block. The camshaft sprocket, mounted to the front of the cam- shaft is driven by the crankshaft sprocket through a camshaft timing chain.

  • Page 36: Cleaning

    Engine — 5.0 & 5.7 Litre • Power Steering Pump • Alternator • Distributor • Water Supply Pump • Accessory Brackets and Electrical Wiring • Starter Motor Cleaning Remove the engine accessories before cleaning to provide better access to the engine’s exterior surfaces. After removing the distrib- utor, accessory brackets, etc., cover the openings with tape to pre- vent the entry of contaminants.

  • Page 37: Draining The Engine

    Engine — 5.0 & 5.7 Litre Draining The Engine Raw Water Cooled Engines With the engine turned off, locate and open the engine drain petcocks located on both sides of the engine block. NOTICE! Probe the drains with a wire to ensure rust particles have not blocked the drain.
  • Page 38 Engine — 5.0 & 5.7 Litre Remove drain plugs from exhaust manifolds. After the water has completely drained, reinstall the drain plugs and torque to 29 N•m (22 lb. ft.). NOTICE! Probe the drains with a wire to ensure rust particles have not blocked the drain.
  • Page 39 Engine — 5.0 & 5.7 Litre Loosen the hose clamp on the lower fuel cell cooling line and remove hose from fuel cell. Allow water to drain from hose. Reinstall all hoses and secure all clamps in the same orienta- tion as removed.

  • Page 40: Engine Lubrication

    Engine — 5.0 & 5.7 Litre Remove drain plugs from exhaust manifolds. Probe the drains with a wire to ensure rust particles have not blocked the drain. After water is completely drained, reinstall drain plugs and tighten securely. Engine Lubrication 67757 Full pressure lubrication, through a full-flow oil filter is supplied by a gear-type...

  • Page 41: Exhaust Manifold

    Engine — 5.0 & 5.7 Litre element unit with an anti-drain back valve. An oil filter bypass valve is used to ensure adequate oil supply, in the event the fil- ter becomes plugged or develops excessive pressure drop. Filtered oil flows into the main gallery and then to the camshaft, bal- ance shaft, rear bearing, and crankshaft bearings.
  • Page 42 Engine — 5.0 & 5.7 Litre Install a new gasket and high rise elbow to manifold. Tighten bolts to 12-18 ft. lb. (16-24 N•m). NOTICE! Clean threads in the mounting holes are critical for torquing of the riser bolts and the seal between the riser and manifold.

  • Page 43: Starter

    Engine — 5.0 & 5.7 Litre Each area/section of gasket mounting surface (see example in pic- ture) should be flat and smooth to a tolerance of 0.1mm. If the surface can not be cleaned or sanded to this tolerance, the part must be machined flat at the gasket mounting surface.
  • Page 44 Engine — 5.0 & 5.7 Litre Remove starter mounting bolts. Remove starter. 22518 Installation Hold stater against engine mounting pad with mounting holes aligned. Install starter bolts and tighten to 41-49 Nm (30-36 ft.lb). 22518 Connect accessory wires (5) to solenoid. Install solenoid extension nut (4) and washer on solenoid termi- nal.

  • Page 45: Intake Manifold

    If the engine has closed cooling installed, remove drain plugs from engine block. Catch the coolant from the engine and dis- pose of properly. NOTICE! Volvo Penta closed cooling system engines come filled with Ethylene Glycol coolant. Follow all local regulations for the disposal of Ethylene Glycol anti- freeze.

  • Page 46: Remove Distributor, Gi And Gxi Models

    Engine — 5.0 & 5.7 Litre Remove Distributor, Gi and GXi Models GL Models: See Electric, Fuel and Ignition Workshop Manual. Disconnect distributor high tension leads and ignition primary lead from distributor cap. Remove the distributor cap bolts and discard. Remove the distributor cap.
  • Page 47 Engine — 5.0 & 5.7 Litre Scribe a line on distributor housing and intake manifold for reas- sembly in the same position. 23089 Loosen hold down clamp and remove the distributor. 23321 Remove Distributor and discard Gasket. Disconnect and remove alternator. Remove Fuse box.

  • Page 48: Disassemble Intake Manifold (Gi, Gxi, Osi, & Osxi)

    Engine — 5.0 & 5.7 Litre Remove intake manifold attaching bolts. Lift manifold from engine. Discard front and rear seals and gaskets. NOTICE! If manifold is to be replaced, transfer: carburetor or throttle body, fuel rail assemblies, thermostat and housing (use new gasket), throttle cable anchor block assembly, distributor clamp and temperature sending unit.
  • Page 49 Engine — 5.0 & 5.7 Litre Remove Thermostat housing bolts. 23312 Remove Thermostat housing and discard gasket. 23313 Remove MAT/MAP sensor stud and remove sensor from mani- fold. 23314 Remove four retaining studs and remove fuel rail assembly. 23315 VPA 7748089 English 09-2007...
  • Page 50 Engine — 5.0 & 5.7 Litre Remove upper intake manifold attaching bolts. 23316 Remove upper intake manifold. Remove and discard upper intake manifold to lower intake manifold gasket. 23317 Remove impulse limiter. 23318 Clean and Inspect Wear Safety Glasses Clean the upper intake manifold in cleaning solvent. Dry with compressed air.

  • Page 51: Assemble Intake Manifold

    Place the upper intake onto the lower intake manifold. 23317 NOTICE! If reusing the fasteners, apply threadlock Volvo Penta P/N 1161053 or equivalent to the threads of the fuel meter body bracket bolt. Install upper intake manifold bolts.
  • Page 52 Apply a 4.0 mm (0.157 in) patch of adhesive Volvo Penta P/N 1161277 or equivalent to the cylinder head side of the lower intake manifold gasket at each end.

  • Page 53: Distributor Installation

    Engine — 5.0 & 5.7 Litre Install the intake manifold assembly onto the engine block. If reusing the fasteners, apply threadlock Volvo Penta P/N 1161053 or equivalent to the threads of the manifold bolts. Install the manifold bolts. 23291 Tighten: NOTICE! Proper lower intake manifold fastener tightening se- quence and torque is critical.
  • Page 54 Engine — 5.0 & 5.7 Litre Gi and GXi models GL models: See Electric, Fuel and Ignition Workshop Manual. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer (1) are aligned with the tabs on the engine front cover (2) and the number 1 piston is at top dead center of the compression stroke.
  • Page 55 Engine — 5.0 & 5.7 Litre Align the indent hole on the distributor gear with the paint mark on the distributor housing. Align the slotted tang in the oil pump driveshaft with the distribu- tor driveshaft. Rotate the oil pump driveshaft with a screwdriver if necessary.
  • Page 56 Engine — 5.0 & 5.7 Litre Install the distributor and distributor clamp. The flat in the dis- tributor housing must be pointing toward the front of the engine. Once the distributor is fully seated, align the distributor rotor segment with the number 8 pointer (1) that is cast into the dis- tributor base.
  • Page 57 Engine — 5.0 & 5.7 Litre Install the distributor cap and NEW distributor cap bolts.Tighten the screws to 2.4 N.m (21 lb. in). Set timing, GL Models see Electrical Fuel and Ignition Work- shop Manual. Gi and GXi Models see EFI Diagnostic Work- shop Manual, On Board Repair.

  • Page 58: Rocker Arm Cover

    Engine — 5.0 & 5.7 Litre Rocker Arm Cover Remove: Valve rocker arm cover bolts. Valve rocker arm cover. Gasket. 39119 Clean: Parts in solvent. Remove all sludge and varnish. Old gaskets from the gasket surfaces. Inspect: Gasket flanges for bending or damage. Rubber grommets and parts for deterioration.
  • Page 59 Engine — 5.0 & 5.7 Litre Remove pushrods and keep in order with the valve lifters and rocker arms. 51055 Remove valve lifter retainer bolts and valve guide retainer. 11508 Remove the valve guides and valve lifters. 11509 VPA 7748089 English 09-2007...
  • Page 60 Engine — 5.0 & 5.7 Litre Remove the lifters one at a time using J 9290-01/J 3049 or equivalent and place them in an organizer rack. Store all reusable components in an exact order, so they may be reassembled in the same wear pattern location from which they were removed.

  • Page 61: Valve Lifters And Guides Clean And Inspect

    Engine — 5.0 & 5.7 Litre Inspect the valve push rods for the following: • Restriction of the oil passage (1) • Wear or scoring of the end contact surfaces (2). The end contact surfaces must be smooth with no scoring or exces- sive wear.

  • Page 62: Valve Lifter Installation

    Engine — 5.0 & 5.7 Litre NOTICE! Lubricate the valve lifter bodies and roller with GM En- gine Oil Supplement, P/N 1052367, or equivalent. Valve Lifter Installation Apply lubricant GM P/N 12345501 or equivalent to the valve lifter rollers. NOTICE! If reusing the valve lifters, install the valve lifters in the original positions.

  • Page 63: Install Rocker Arm Assemblies

    Engine — 5.0 & 5.7 Litre Install Rocker Arm Assemblies Install the following components: • Install the valve rocker arms (3) • Install the rocker arm balls (2) • Install the valve rocker arm nuts (1) 182835 Valve Lash Adjustment Turn the valve rocker arm nuts clockwise until all of the valve lash is removed.

  • Page 64: Valve Rocker Arm Cover Installation

    Engine — 5.0 & 5.7 Litre Turn the crankshaft clockwise 1 revolution until the alignment mark on the crankshaft balancer is aligned with the notch in the engine front cover tab. 195336 With the engine in the number 6 cylinder firing position, adjust the exhaust valves for cylinder numbers 2, 5, 6 and 7 and the intake valve for cylinder numbers 3, 4, 6 and 8 using the follow- ing process:...
  • Page 65 Engine — 5.0 & 5.7 Litre Remove spark plugs. 317307 Remove cylinder head bolts. NOTICE! Place cylinder head on two wooden blocks to prevent damage. 317217 Remove cylinder heads. 317227 Remove and discard head gaskets. 317233 VPA 7748089 English 09-2007...

  • Page 66: Cylinder Head Disassemble And Recondition

    Engine — 5.0 & 5.7 Litre If required, remove the dowel pin (cylinder head locator). 182846 Cylinder Head Disassemble Tool Required: J 8062 Valve Spring Compressor and Recondition Disassemble: Compress the springs with J 8062. CAUTION! Wear safety glasses. Compressed valve springs have high tension against the valve spring compressor.

  • Page 67: Cylinder Head Clean And Inspect

    Engine — 5.0 & 5.7 Litre Remove the valve stem keys (1). Remove the J 8062 from the cylinder head. Remove the valve spring cap (2). Remove the valve spring (3). Remove the valve stem oil seal (4). Discard the valve stem oil seal. Remove the valve.

  • Page 68: Valve Spring Straightness

    Engine — 5.0 & 5.7 Litre • External cracks in the water chambers • Restrictions in the intake or exhaust passages • Restrictions in the cooling system passages • Rusted, damaged or leaking core plugs Inspect: Measure the cylinder head for warping with a straight edge and feeler gauge •...

  • Page 69: Valve Stems

    Engine — 5.0 & 5.7 Litre Valve Stems Valve stems (1) with excessive valve guide (2) clearance must be repaired or the cylinder head replaced. Measure the valve stem-to-guide clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness.

  • Page 70: Valve Guide Reaming And Seat Grinding

    Engine — 5.0 & 5.7 Litre Valve Guide Reaming and Seat Grinding Measuring: Tools Required: J 5830-02 Valve Guide Reamer Set J 8001 Dial Indicator Set Measure the valve stem-to-guide clearance. See Cylinder Head Clean and Inspect on page 63.. J-8001 Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption.
  • Page 71 Engine — 5.0 & 5.7 Litre Reaming: CAUTION! Wear Safety Glasses. NOTICE! Exhaust valves with excessive valve stem-to-guide clearance must be replaced with the available service valve that has an 0.0774 mm (0.0305 in) oversize valve J-5830-3 stem. The intake valves are NOT available with over- size valve stems.

  • Page 72: Valve Rocker Arm Stud Removal

    Engine — 5.0 & 5.7 Litre Inspect the valve contact surface for the following: • Undersized margin (1) • Pitted surfaces (2) • Burnt or eroded areas (3) • Acceptable edge (margin) (4) Valves with excessive damage must be replaced. Minor imperfections of the valve or valve seat may be repaired.

  • Page 73: Valve Rocker Arm Stud Installation

    Engine — 5.0 & 5.7 Litre Place the J 5802-01 over the valve rocker arm ball stud to be removed. Install a nu and a flat washer. Rotate the clockwise t remove the valve rocker arm ball stud. J 5802-01 66507 Valve Rocker Arm Stud Installa- tion...

  • Page 74: Cylinder Head Assemble

    Engine — 5.0 & 5.7 Litre Use J 6880 and a hammer to install the valve rocker arm ball stud into place. The valve rocker arm ball stud is installed to proper depth when the J 6880 bottoms onto the cylinder head. J 6880 66504 Cylinder Head Assemble...
  • Page 75 Engine — 5.0 & 5.7 Litre Install the valve stem oil seal onto the valve guide using the J- 42073. Tap the valve stem oil seal onto the valve guide until the J- 42073 bottoms against the valve spring seat. Inspect the valve stem oil seal.
  • Page 76 Engine — 5.0 & 5.7 Litre Use the J 8062 in order to compress the valve springs. Install the valve stem keys. J-8062 Use grease in order to hold the valve stem keys in place while disconnecting the J 8062. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem.
  • Page 77 Engine — 5.0 & 5.7 Litre Install the cylinder head onto the cylinder block. Guide the cylin- der head carefully into position over the locator pins and the cyl- inder head gasket. 317227 Apply sealant 1141570 or equivalent to the threads of the cylin- der head bolts.

  • Page 78: Oil Pan And Oil Pump

    Engine — 5.0 & 5.7 Litre Oil Pan and OIl Pump Drain oil from engine. See Draining The Engine on page 33. Remove engine from boat. See Removal and Installation Work- shop Manual. Removal Disconnect and remove the dipstick tube. Discard the O-rings (1) and seals (2).

  • Page 79: Oil Pan Clean And Inspect

    Engine — 5.0 & 5.7 Litre Remove and discard the oil pan gasket. 23305 Oil Pan Clean and Inspect CAUTION! Wear safety glasses. Clean the oil pan baffle in cleaning solvent. Dry the oil pan and the oil pan baffle with compressed air. Inspect the oil •...
  • Page 80 Engine — 5.0 & 5.7 Litre Oil Pump Removal Remove the nuts (6) and the crankshaft oil deflector (2). Remove the oil pump bolt (1). Remove the oil pump (3), the oil pump driveshaft (5) and the oil pump driveshaft retainer (4). Separate the oil pump (3), the oil pump driveshaft (5) and the oil pump driveshaft retainer (4).

  • Page 81: Oil Pump Disassemble

    Engine — 5.0 & 5.7 Litre Oil Pump Disassemble Remove the oil pump driveshaft and retainer. 5274 Remove oil pump screen (if necessary) • The oil pump screen has a press fit into the oil pump cover. • DO NOT remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a unit.

  • Page 82: Oil Pump Clean And Inspect

    Engine — 5.0 & 5.7 Litre Remove the oil pump cover 5277 Remove the oil pump drive gear and the oil pump driven gear. Match mark the gears for reassembly. 5278 Remove the oil pressure relief valve retaining pin (1) Remove the oil pressure relief spring (2).
  • Page 83 Engine — 5.0 & 5.7 Litre — Wear • Scoring, damage or casting imperfections to the body (3) • Damaged or scored gear shaft (4) • Damaged or scored gear shaft (5) • Damaged bolt hole threads • Worn oil pump driveshaft bore •...
  • Page 84 Engine — 5.0 & 5.7 Litre Install the pump cover. 5277 Install the oil pump cover bolts. Tighten the bolts to 12 N•m (106 lb. in). Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand. 5276 Install the oil pump screen.
  • Page 85 Engine — 5.0 & 5.7 Litre NOTICE! DO not reuse the oil pump driveshaft retainer (4). During assembly, install a NEW oil pump driveshaft retainer. Assemble the oil pump (3), the oil pump driveshaft (5) and a NEW oil pump driveshaft retainer (4). Install the oil pump (3).
  • Page 86 Engine — 5.0 & 5.7 Litre Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive Volvo Penta P/N 1161277 or equivalent to both the (0.197”) right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces.
  • Page 87 Engine — 5.0 & 5.7 Litre Install the oil pan onto the engine block. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing. Slide the oil pan back against a suitable straight edge. 182851 Using new seals and O-rings, install the dipstick tube.

  • Page 88: Water Pump

    Engine — 5.0 & 5.7 Litre Water Pump Removal Tools Required J41240 Fan Clutch Remover and Installer Release tension on the bent tensioner and remove the serpen- tine belt from the water pump pulley. NOTICE! It is not necessary to remove the belt from the rest of the other pulleys unless the belt is worn or deteriorat- Remove the bolts and the water pump pulley using the J41240 or suitable substitute.
  • Page 89 Engine — 5.0 & 5.7 Litre Installation Tools Required J41240 Fan Clutch Remover and Installer If reusing the fasteners, apply sealant 1141570 or equivalent to the threads of the water pump bolts. Clean any residual gasket material from cooling ports on the engine.
  • Page 90 Engine — 5.0 & 5.7 Litre Remove Loosen power steering pump nut. 22916 Loosen power steering pump bolt. 22915 Loosen power steering pump pivot nut. Pull up on power steering pump belt to loosen belt tension and remove the belt. 22919 VPA 7748089 English 09-2007...
  • Page 91 Engine — 5.0 & 5.7 Litre Loosen alternator pivot bolt. 22914 Loosen alternator belt tension bolt. Pull on alternator belt to loosen the alternator and remove the belt. 22918 Tools Required J 41240 Fan Clutch Remover and Installer Remove the bolts and the fan and water pump pulley using the J41240.

  • Page 92: Water Pump Installation

    Engine — 5.0 & 5.7 Litre Water Pump Installation Tools Required J 41240 Fan Clutch Remover and Installer If reusing the fasteners, apply sealant 1141570 or equivalent to the threads of the water pump bolts. Install the water pump and the NEW water pump gaskets. Install the water pump bolts.

  • Page 93: Crankshaft Balancer

    Engine — 5.0 & 5.7 Litre Crankshaft Balancer Removal Disconnect hoses from raw water pump. Remove raw water pump retaining bolts and remove the pump. Remove water pump stay bracket. VPA 7748089 English 09-2007...

  • Page 94: Crankshaft Balancer Inspect

    Engine — 5.0 & 5.7 Litre Remove the crankshaft balancer bolt and washer. Tools Required J23523-F Balancer Remover and Installer. Use the J23523-F in order to remove the crankshaft balancer. Install the J 23523-F plate and bolts onto the crankshaft bal- ancer.
  • Page 95 Apply a small amount of adhesive Volvo Penta P/N 1161277 or equivalent onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint.

  • Page 96: Engine Front Cover

    Engine — 5.0 & 5.7 Litre Install the water pump stay bracket. Install raw water pump and pulley. Tighten bolts to 33-39 N•m (25-29 ft. lb.) Install water pump retaining bracket Install water hoses in the correct orientation and tighten clamps NOTICE! Crossing the raw water hoses will damage the water pump impeller and engine.
  • Page 97 Engine — 5.0 & 5.7 Litre Removal Remove the crankshaft position sensor bolt. Remove the crankshaft position sensor. Remove and discard the crankshaft position sensor seal (O- ring). Remove engine front cover bolts and front cover. NOTICE! The engine front cover is made of composite material and has an intergral gasket.

  • Page 98: Engine Front Cover Installation

    Engine — 5.0 & 5.7 Litre Engine Front Cover Installation NOTICE! The engine front cover is made of composite material and has an intergral gasket. Once the front cover is re- moved, it must be discarded and a new front cover must be used.
  • Page 99 Engine — 5.0 & 5.7 Litre J 5825-A Crankshaft Gear Remover Remove engine front cover. See Engine Front Cover on page Remove the crankshaft position sensor reluctor ring. 69450 Check the camshaft timing chain free play. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2).
  • Page 100 Engine — 5.0 & 5.7 Litre Remove the crankshaft sprocket using the J 5825-A. 11506 Remove the crankshaft balancer key. 182847 Inspection Clean the components with cleaning solvent. Dry the components with compressed air. CAUTION! Always wear safety glasses when using compressed air.
  • Page 101 Engine — 5.0 & 5.7 Litre Inspect the camshaft sprocket and the crankshaft sprocket for the following: • Broken teeth (1) • Damaged teeth (2) • Chipped teeth (3) • Worn teeth • Uneven wear on the edge of the teeth •...
  • Page 102 Engine — 5.0 & 5.7 Litre Align the keyway of the crankshaft sprocket with the crankshaft balancer key. CAUTION! Wear safety glasses. Use the J 5590 to install the crankshaft sprocket. 32066 Rotate the crankshaft until the crankshaft sprocket is at the 12 o’clock position.

  • Page 103: Camshaft

    Engine — 5.0 & 5.7 Litre Install the crankshaft position sensor reluctor ring. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. Use the J 5590 in order to push the crankshaft position sen- sor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket.
  • Page 104 Engine — 5.0 & 5.7 Litre Dry the engine camshaft with compressed air. CAUTION! Always wear safety glasses when using compressed air. Inspect the camshaft retainer plate for damage. If the camshaft retainer plate is damaged, replace as necessary. Inspect the camshaft bearings for correct fit into the engine block camshaft bearing bores.

  • Page 105: Camshaft Bearings

    Engine — 5.0 & 5.7 Litre Installation Apply clean engine oil GM P/N 12345610 or equivalent, or engine oil supplement GM P/N 1052367 or equivalent to the fol- lowing components: • The engine camshaft lobes • The camshaft bearing journals •...
  • Page 106 Engine — 5.0 & 5.7 Litre NOTICE! A loose camshaft bearing may be caused by an en- larged, out-of-round or damaged engine block cam- shaft-bearing bore. NOTICE! Always remove the camshaft inner bearings #2 and #3 first. The camshaft outer bearings #1 and #4 serve as a guide for the J 33049.
  • Page 107 Engine — 5.0 & 5.7 Litre Remove the camshaft outer bearings #1 and #5. Insert the J 33049 into the camshaft outer bearing #1. Tighten the J 33049 expander assembly nut until snug. Drive the camshaft outer bearing #1 from the camshaft outer bearing bore #1.
  • Page 108 Engine — 5.0 & 5.7 Litre CAUTION! Wear safety glasses. NOTICE! The camshaft bearings vary in size. When ordering the new camshaft bearings, be sure to order the cor- rect camshaft bearings for the application to be ser- viced. NOTICE! Always install the camshaft outer bearings #1 and #4 first.

  • Page 109: Piston, Connecting Rod, And Bearings

    Engine — 5.0 & 5.7 Litre Carefully slide the J 33049 until the J 33049 expander assembly is positioned between the camshaft inner bearing bore #3 and the camshaft inner bearing bore #2. Install the NEW camshaft inner bearing #3 onto the J33049 expander assembly.
  • Page 110 Engine — 5.0 & 5.7 Litre Use the J 24270 in order to remove the cylinder ring ridge. Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use the J 24270 to remove all of the cylinder ring ridge. Turn the crankshaft so the piston is at the top of the stroke.

  • Page 111: Piston And Connecting Rod Disassemble

    Engine — 5.0 & 5.7 Litre NOTICE! Always assemble the connecting rod caps to the matching connecting rods. Remove the connecting rod bearings. Keep the connecting rod bearings with the original connect- ing rod and connecting rod cap. Wipe the oil from the connecting rod bearings. Wipe the oil from the crankpin.

  • Page 112: Clean And Inspect

    Engine — 5.0 & 5.7 Litre Press the piston pin from the connecting rod using the J 24086- The piston pin has an interference fit into the connecting rod, J 24086-C and is full floating in the piston. 4965 Mark separate, and organize the parts for assembly. 34671 Clean and Inspect NOTICE! Measurement of all components should be taken with...
  • Page 113 Engine — 5.0 & 5.7 Litre Clean the piston oil lubrication holes and slots. Inspect the piston for the following: • Eroded areas (1) on the top of the piston • Scuffed or damaged skirt (2) • Damage to the pin bore (3) •...
  • Page 114 Engine — 5.0 & 5.7 Litre To determine piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore. To determine the piston pin-to-bore clearance, subtract the pis- ton pin diameter from the piston pin bore diameter. Engine Specifications 5.0 Litre on page 139 4975 Measure the piston with a micrometer at a right angle to the pis-...

  • Page 115: Piston Selection

    Engine — 5.0 & 5.7 Litre Inspect the connecting rod for twisting. Inspect the connecting rod for damage to the bearing cap and bolt threads. 156169 Measure the piston compression ring end gap. NOTICE! Fit each compression ring to the cylinder in which it will be used.
  • Page 116 Engine — 5.0 & 5.7 Litre Measure the J 8087 with a micrometer and record the reading. J 8087 4974 With a micrometer or caliper at a right angle to the piston pin bore, measure the piston 11 mm (0.433 in) from the bottom of the skirt.
  • Page 117 Engine — 5.0 & 5.7 Litre Lubricate the piston pin bores with clean engine oil. Use a torch and apply MILD heat to the piston pin end of the connecting rod. Use the J 24086-C in order to press the piston pin into the piston and connecting rod assembly.
  • Page 118 Engine — 5.0 & 5.7 Litre Installation Apply clean engine oil to the following components: • The piston • The piston rings • The cylinder bore • The bearing surfaces Install the J 5239 onto the connecting rod bolts. Install the J 8037 onto the piston and compress the piston rings. NOTICE! J 8037 has tabs on the bottom of the ring compressor to prevent the tool from sliding into the cylinder with the piston.
  • Page 119 Engine — 5.0 & 5.7 Litre Use the J 8037 and the J 5239 and lightly tap the top of the pis- ton with a wooden hammer handle. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore.

  • Page 120: Engine Coupler

    Engine — 5.0 & 5.7 Litre After the piston and connecting rod assemblies have been installed, then lightly tap each connecting rod assembly (paral- lel to the crank pin) in order to ensure that the connecting rods have side clearance. Use a feeler gauge or a dial indicator to measure the connect- ing rod side clearance between the connecting rod caps.
  • Page 121 Engine — 5.0 & 5.7 Litre Remove nut, lock washer, and ground leads from ground stud and power steering cooler bolt. Unscrew remaining flywheel housing bolts, lock washers and washers. Note position of clamps so they can be installed in original position.
  • Page 122 Engine — 5.0 & 5.7 Litre Installation Slide coupler onto crankshaft studs. Install new locknuts. NOTICE! If studs are loose or show any signs of movement they must be replaced. The threaded portion of the stud should not have any play in the crankshaft. If studs are replaced, they must be locked in place us- ing VP P/N 1161075 thread locking compound and torqued to 10-15 ft.

  • Page 123: Flywheel

    Engine — 5.0 & 5.7 Litre Slide flywheel cover into place. Install screws and tighten them to 7-9 N•m (60-84 in. lb.) Install engine, see Engine Installation and Removal Workshop Manual. 20034 Flywheel Removal Engine coupler, Engine Coupler on page 116 Remove flywheel from crankshaft studs.

  • Page 124: Crankshaft Rear Oil Seal And Housing

    Engine — 5.0 & 5.7 Litre Inspection Inspect the engine flywheel for the following: • Cracks other surface damage (1) • Damaged ring gear teeth (2) • Loose or improperly positioned ring gear The ring gear has an interference fit onto the engine flywheel and the ring gear should be positioned completely flat against the flange of the engine flywheel.
  • Page 125 Engine — 5.0 & 5.7 Litre If removing oil seal housing, remove oil pan. See Oil Pan and OIl Pump on page 74. Remove the crankshaft rear oil seal housing nut and bolts. Remove the crankshaft rear oil seal housing. Remove the crankshaft rear oil seal housing gasket.
  • Page 126 Engine — 5.0 & 5.7 Litre Install the crankshaft rear oil seal housing onto the crankshaft rear oil seal housing retainer stud. Install the crankshaft rear oil seal housing nut and bolts. Tighten nut and bolts to 12 N•m (106 lb. in). Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing.

  • Page 127: Crankshaft

    Engine — 5.0 & 5.7 Litre Install flywheel. See Flywheel on page 119. Install engine coupler. See Engine Coupler on page 116. Install engine in boat. See Engine Specifications 5.0 Litre on page 139. Crankshaft Remove Remove engine from boat. See Removal and Installation Work- shop Manual.

  • Page 128: Crankshaft And Bearings Clean And Inspect

    Engine — 5.0 & 5.7 Litre Remove the crankshaft bearings from the crankshaft bearing caps. 317295 Remove the crankshaft bearings from the engine block. 317292 Crankshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Dial Indicator J 36660 Electronic Torque Angle Meter CAUTION! Wear safety glasses.
  • Page 129 Engine — 5.0 & 5.7 Litre Inspect the crankshaft for the following: • Crankshaft journals (1) should be smooth with no evidence of scoring or damage. • Deep grooves (2) • Scratches or uneven wear (3) • Pitted surfaces (4) •...
  • Page 130 Engine — 5.0 & 5.7 Litre Measure the crankshaft end play. NOTICE! In order to properly measure the crankshaft end play, the crankshaft, the crankshaft bearings and the crankshaft bearing caps, the crankshaft bearing cap bolts must be installed into the engine block and the bolts tightened to specifications.

  • Page 131: Bearing Clearance Measuring Procedures

    Engine — 5.0 & 5.7 Litre Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings. • If the lower half of the crankshaft bearing is worn or dam- aged, both the upper and lower halves of the crankshaft bearing should be replaced.
  • Page 132 Engine — 5.0 & 5.7 Litre Install the crankshaft bearings into the crankshaft bearing caps. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Install the crankshaft bearing cap bolts.
  • Page 133 Engine — 5.0 & 5.7 Litre Install the crankshaft. 317351 Install the gauging plastic the full width of the journal. 500655 Install the crankshaft bearings into the crankshaft bearing caps. 317295 VPA 7748089 English 09-2007...
  • Page 134 Engine — 5.0 & 5.7 Litre Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Install the crankshaft bearing cap bolts. Tighten the crankshaft bearing cap bolts on the first pass to 20 N•m (15 lb.
  • Page 135 Engine — 5.0 & 5.7 Litre Crankshaft and Bearings Installation Tools Required J 36660 Electronic Torque Angle Meter Install the crankshaft bearings into the engine block. Apply clean engine oil to the crankshaft bearings. 317292 Apply clean engine oil to the crankshaft bearing journals. Install the crankshaft.
  • Page 136 Engine — 5.0 & 5.7 Litre Install the crankshaft bearing caps in the original position and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Install the crankshaft bearing cap bolts and the crankshaft bear- ing cap studs.

  • Page 137: Recondition Engine Block

    Engine — 5.0 & 5.7 Litre Install flywheel. See Flywheel on page 119. Install engine coupler. See Engine Coupler on page 116. Install starter. See Starter on page 39. Install engine in boat. See Removal and Installation Workshop Manual. Recondition Engine Block Engine Block Plug Removal Remove the engine oil pressure sensor and fitting.
  • Page 138 Engine — 5.0 & 5.7 Litre Remove the square socket plugs (engine block oil gallery) from the rear of the engine block. 69847 Remove the left side rear and left rear top engine block oil gal- lery plugs. 182841 Remove the expansion cup plug (camshaft rear bearing hole) and discard.
  • Page 139 Engine — 5.0 & 5.7 Litre Remove the spring type S pin (crankshaft rear oil seal housing locator if required). 334323 Remove the engine block core hole plugs. Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket.

  • Page 140: Engine Block Clean And Inspect

    Engine — 5.0 & 5.7 Litre Engine Block Clean and inspect Tools Required J 8087 Cylinder Bore Gauge CAUTION! Wear safety glasses. Clean all the remaining sealing or gasket material from the seal- ing surfaces. Clean the engine block with cleaning solvent. Flush the engine block with clean water or steam.

  • Page 141: Cylinder Boring And Honing

    Engine — 5.0 & 5.7 Litre Measure the cylinder bores for taper and out-of-round. Depress the plunger on the J 8087 7 mm (0.275 in) or until the J 8087 enters the cylinder bore. Center the J 8087 in the cylinder bore and turn the indicator dial to 0.

  • Page 142: Boring Procedure

    Engine — 5.0 & 5.7 Litre Scrub the cylinder bores with a stiff bristle brush. Rinse the cylinder bores thoroughly with clean hot water. Dry the cylinder bores with a clean rag. Do not allow any abrasive material to remain in the cylinder bores.

  • Page 143: Engine Specifications 5.0 Litre

    Engine — 5.0 & 5.7 Litre Engine Specifications 5.0 Litre Engine Mechanical Specifications 5.0 litre Application Metric English General Data Engine Type Displacement 5.0 L 305 CID Bore 94.89 mm 3.737 in. Stroke 88.39 3.480 Compression Ratio 9.4:1 Firing Order 1-8-4-3-6-5-7-2 Spark Plug Gap 1.52 mm...
  • Page 144 Engine — 5.0 & 5.7 Litre Engine Mechanical Specifications 5.0 litre Application Metric English Crankshaft Bearing Clearance (Journal #1-Service) 0.025-0.051 mm 0.0010-0.0020 in Crankshaft Bearing Clearance (Journal #2, #3 and #4-Service) 0.025-0.064 mm 0.0010-0.025 in Crankshaft Bearing Clearance (Journal #5-Service) 0.038-0.063 mm 0.0015-0.0025 in Crankshaft End Play...
  • Page 145 Engine — 5.0 & 5.7 Litre Engine Mechanical Specifications 5.0 litre Application Metric English Clearance in Piston (Service) 0.013-0.023 mm 0.0005-0.0009 in Diameter 23.545-23.548 mm 0.9270-0.9271 in Fit in Connecting Rod 0.021-0.040 mm 0.0008-0.0016 in (Interference) (Interference) Piston Rings (End Gap Measured in Cylinder Bore) Piston Compression Ring Gap (Top Groove) 0.25-0.40 mm 0.010-0.016 in...
  • Page 146 Engine — 5.0 & 5.7 Litre Engine Mechanical Specifications 5.0 litre Application Metric English Valve Stem Clearance (Exhaust-Service) 0.025-0.094 mm 0.0010-0.0037 in Valve Stem Clearance (Intake-Service) 0.025-0.094 mm 0.0010-0.0037 in Valve Stem Diameter 8.661-8.679 mm 0.3410-0.3416 in Valve Stem Oil Seal Installed Height (Measured from the Top of 1-2 mm 0.03937-0.07874 in the Large Diameter Valve Guide Bevel to the Bottom of the Valve...

  • Page 147: Engine Specifications 5.7 Litre

    Engine — 5.0 & 5.7 Litre Engine Specifications 5.7 Litre Engine Mechanical Specifications 5.7 litre Application Metric English General Data Engine Type Displacement 5.7 L 350 CID Bore 101.63 mm 4.0012 in. Stroke 88.39 3.480 Compression Ratio 9.4:1 Firing Order 1-8-4-3-6-5-7-2 Spark Plug Gap 1.52 mm...
  • Page 148 Engine — 5.0 & 5.7 Litre Engine Mechanical Specifications 5.7 litre Application Metric English Crankshaft Bearing Clearance (Journal #1-Service) 0.025-0.051 mm 0.0010-0.0020 in Crankshaft Bearing Clearance (Journal #2, #3 and #4-Service) 0.025-0.064 mm 0.0010-0.025 in Crankshaft Bearing Clearance (Journal #5-Service) 0.038-0.063 mm 0.0015-0.0025 in Crankshaft End Play...
  • Page 149 Engine — 5.0 & 5.7 Litre Engine Mechanical Specifications 5.7 litre Application Metric English Clearance in Piston (Service) 0.013-0.023 mm 0.0005-0.0009 in Diameter 23.545-23.548 mm 0.9270-0.9271 in Fit in Connecting Rod 0.021-0.040 mm 0.0008-0.0016 in (Interference) (Interference) Piston Rings (End Gap Measured in Cylinder Bore) Piston Compression Ring Gap (Top Groove) 0.25-0.40 mm 0.010-0.016 in...
  • Page 150 Engine — 5.0 & 5.7 Litre Engine Mechanical Specifications 5.7 litre Application Metric English Valve Stem Clearance (Exhaust-Service) 0.025-0.094 mm 0.0010-0.0037 in Valve Stem Clearance (Intake-Service) 0.025-0.094 mm 0.0010-0.0037 in Valve Stem Diameter 8.661-8.679 mm 0.3410-0.3416 in Valve Stem Oil Seal Installed Height (Measured from the Top of 1-2 mm 0.03937-0.07874 in the Large Diameter Valve Guide Bevel to the Bottom of the Valve...

  • Page 151: Fastener Tightening Specifications

    Engine — 5.0 & 5.7 Litre Fastener Tightening Specifications Fastener Tightening Specifications Application Metric (N•m) English Camshaft Retainer Bolt 106 in. lb. Camshaft Sprocket Bolt 18 ft. lb. Connecting Rod Nut First Pass 20 ft. lb. Final Pass 55 Degrees Crankshaft Balancer Bolt 70 ft.
  • Page 152 Engine — 5.0 & 5.7 Litre Fastener Tightening Specifications Application Metric (N•m) English Engine Coolant Temperature Sensor 15 ft. lb. Engine Flywheel and Coupler Nut 54 - 61 40-45 ft. lb. Engine Front Cover Bolt 106 in. lb. Engine Mount Bracket Bolt to Engine 34-39 25-29 ft.
  • Page 153 Engine — 5.0 & 5.7 Litre Fastener Tightening Specifications Application Metric (N•m) English Oil Pan Baffle Bolt 106 in. lb. Oil Pan Stud 53 in. lb. Oil Pan Stud Nut 18 ft. lb. Oil Pan Bolt or Stud 106 in. lb. Oil Pan Dipstick Adapter (Drain Hole) 37 ft.

  • Page 154: Sealants, Adhesives And Lubricants

    Engine — 5.0 & 5.7 Litre Sealants, Adhesives and Lubricants Sealants, Adhesives and Lubricants Application Type of Material Part No. Camshaft Retainer Bolt Threadlock 1161053 Crankshaft Balancer Keyway Adhesive 1161277 Cylinder Head Bolt Sealant 1141570 Engine Block to the Crankshaft Rear Oil Seal Housing Adhesive 1161277 Junction at the Oil Pan Sealing Surfaces...
  • Page 155 10° BTDC (Shunt P/N 885163 required) 5.7GL Ignition Timing 12° BTCD (Shunt P/N 885163 required) 5.0, 5.7GL Spark Plug Volvo Penta P/N 3861632 Tune Up Specifications 5.0GXi, 5.0OSi, 5.7Gi, 5.7OSi, 5.7GXi, 5.7OSXi Model Item Specification 5.0GXi Low Pressure Fuel Pump 8 PSI ±...

  • Page 156: Special Tools

    Engine — 5.0 & 5.7 Litre Special Tools General Motors Special Tools J 7872 J 3049-A Magnetic Base Dial Valve Lifter Remover Indicator J 5239 J 8001 Connecting Rod Bolt Dial Indicator Guide Set J 5590 J 8037 Crankshaft Gear Piston Ring Compres- Installer J 8062...
  • Page 157 Engine — 5.0 & 5.7 Litre General Motors Special Tools J 5830-02 J 8087 Valve Guide Reamer Cylinder Bore Gauge J 8089 J 24086-C Carbon removing Piston Pin brush. Remover/Installer Set J 9666 J 24270 Valve Spring Tester Ridge Reamer J 21882 J 33049 Oil Suction Pipe...
  • Page 158 Engine — 5.0 & 5.7 Litre General Motors Special Tools J 8520 J 36660 Camshaft Lobe Lift Electronic Torque Indicator Angle Meter J 41240 J 5802-01 Fan Clutch Remover Rocker Arm Stud Remover Installer J 42073 J 23738-A Vacuum Valve Stem Seal pump Installer J 6880...
  • Page 159 J 5892-D Piston Ring Groove Valve Spring Compres- Cleaner J 22794 J 5715 or J 6036 Spark Plug Port Reamer Adapter Volvo Penta Special Tool J 43276 888863 Clutch Pilot Bearing Distributor hold down Remover tool VPA 7748089 English 09-2007...
  • Page 160 Material Required Molykote Lubricant ® Permatex No. 2 Volvo Penta Gasket Sealing Compound P/N 1161059 GM Super Engine Oil Supplement 3M Adhesive Plastigage (Green) RTV Sealer API “SJ” SAE 30 Heavy Duty Synthetic Motor Oil VPA 7748089 English 09-2007...
  • Page 161 Safety Section Part A Marine Products and Safety of People Who Use Them ..S-2 Sterndrive Shift System ....... . . S-3 Sterndrive Throttle Control System .

  • Page 162: Marine Products And Safety Of People Who Use Them

    Part A - Marine Products and safety of People Who Use Them Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufac- turers are careful to make sure... Product User is informed. . . Products are safe and reliable.

  • Page 163: Sterndrive Shift System

    Sterndrive Shift System The Shift System starts here at the remote control lever..and ends here at the propeller. What's Most Important? . . . Shift mechanism must match When the control lever is in Forward, Neutral or Reverse position .

  • Page 164: Sterndrive Throttle Control System

    Sterndrive Throttle Control System The throttle Control System starts here and the remote control lever ..and ends here on the engine. What's Most Important? When the control lever is moved from Forward (or Reverse) to Neutral ..

  • Page 165: Sterndrive Steering System

    Sterndrive Steering System The Steering System starts here at the helm . . . What's Most Important? . . . and ends here at the propel- ler on the sterndrive The Steering System . . . must be installed properly must be adjusted properly must be lubricated What Could Happen?
  • Page 166 How Can Loss of Steering Control be Minimized? use steering components which meet marine industry (ABYC) standards . . . In pre- Read, understand, and follow manufacturer's instructions. delivery Assemble parts and make adjustments carefully . . . inspection Closely follow the warnings marked with .
  • Page 167 Sterndrive Fuel and Electrical Systems The electrical System begins here at the battery ..and ends here at the carburetor or fuel injectors The fuel system . . . and ends starts here at the fuel here on the en- tank .
  • Page 168 Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard require- ments. Most automotive parts do not, especially electrical components that must meet ignition protec- tion requirements of the U.S. Coast Guard regulations. When nonmetallic parts look to be in poor shape . . . replace them! Torn Boots! Wires Cracked! Cracked Fuel Lines!
  • Page 169 Follow "Starting Procedure" outlined in the operator's manual. Always make sure there are no gasoline fumes in the engine compartment before starting the engine. Open the compartment and use your nose. Don't gamble. Backfire flame arrestor must be in place and securely attached to the air intake. Do not alter the backfire flame arrestor.
  • Page 170 Summing Up Now you know some things that can take the joy out of enjoyable boating. No doubt about it . . . it takes time! Reading and understanding instructions. Reading and understanding warnings marked with . . . Putting parts together correctly . . . Making correct adjustments .

  • Page 171: Marine Products And Safety Of People Who Fix Them

    Part B - Marine Products and Safety of People* Who Fix Them Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you? Mechanics can be hurt while . . . Servicing boats Servicing sterndrives Troubleshooting problems...

  • Page 172: Handling Lead Acid Batteries

    Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . . you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly! When you smell the other gasses in the exhaust, you are inhaling carbon monoxide.

  • Page 173: Gasoline! Handle With Care

    Battery gas is explosive! Never yank cables off While charging or discharging, battery posts. . . it's a sure remember. . . way to make lots of sparks. . .surrounded by bat- tery gas No Smoking No Flames No Sparks After Charging.

  • Page 174: Hazardous Products

    Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled. Matches, cigarettes, torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights (furnace, dryer, water heater) ????????? How many of these are in your area? Hazardous Products...

This manual is also suitable for:

5.7 gi5.7 gxi5.7 osi5.7 osxi5.0 osi5.0 gxi

Table of Contents