Foreword Models This manual applies to the following engines: Raw Water Cooled Engine Model Spec. No. Displacement 3.0GXi-J 3869389 3.0L 3.0GXiC-J 3869390 5.0GXiC-J 3869351 5.0L 5.0GXiCE-M 21182210 5.7GiC-300–J 3869459 5.7GiCE-300-M 21182213 5.7L 5.7GXiC-J 3869353 5.7GXiCE-M 21189867 8.1GiC-J 3869355 8.1L 8.1GiCE-M...
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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.
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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. 47700387 06-2009...
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.
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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.
EVC Diagnostic Function. If you want to supplement the instrumentation, if your boat is equipped with instruments not described here, or if you are unsure about the functionality of your instrumentation, please contact your Volvo Penta dealer. Main EVC Components...
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EVC system. controls and monitors the engine. B. Helm Station Control Unit (HCU) – This compo- H. Volvo Penta options (not shown) – The following nent handles communication between the instrumen- components can be connected to the EVC system to tation and the controls.
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Presentation Main Station The boat always has one main helm control station. It is the only station equipped with ignition keys. The system voltage must be turned on here to allow sec- ondary stations to be used. Standard instrumentation and controls: 1.
NOTICE! If you want to supplement the instrumenta- tion, your boat is equipped with instruments not descri- bed here, or you are not sure about their functionality, please contact your Volvo Penta dealer or boat dealer. Start/Stop Panel The start/stop panel is situated on stations other than the main station.
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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.
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Instruments and Controls Optional Gauges There is one gauge (of each type) for each engine. All gauges are optional; however, the boat is always equipped with either an EVC System Tachometer with LCD display or an EVC System Display, since at least one of these instruments is needed when modifying EVC settings.
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Instruments and Controls Alarm Display (Optional) There is one alarm display for each engine. A start-up test checks that all lamps are working when the ignition key is first turned to RUN/ON. All the warn- ing lamps should light up during this test. Check that all lamps function.
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Instruments and Controls Battery: Amber Indicator The battery lamp lights up if the alternator is not charg- ing. Stop the engine if this lamp lights up during oper- ation. If the lamp lights up, this can be due to a fault in the electrical system or because the alternator drive 50834 belt is slack.
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Instruments and Controls Control Panel Panel for single engine installations Panel for twin engine installations The buttons on the EVC control panel command the following functions: 1. ACTIVATION BUTTON – This button activates and locks/unlocks a station. As long as no other station is locked, pressing this button the first time activates the station.
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Instruments and Controls Docking Station Panel The docking station is comprised of a joystick A and a control panel B dedicated solely for docking the boat. Directions for using the joystick are provided in the sections entitled Controls and Operation. The docking station panel allows stopping and restart- ing of the engines and fault handling when operating the boat from a docking station.
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Instruments and Controls EVC System Display There are four types of displays. When using EVC, you must have at least one of these display types installed. ● EVC System Tachometer Display – An LCD display integrated into the EVC System Tach- ometer.
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Instruments and Controls EVC Basic Window In the EVC Basic Window, operating information items can be monitored one at a time. It is also in this window that all EVC settings and calibration functions are found. The EVC Basic Window is operated with buttons on the EVC Control Panel.
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Instruments and Controls Multiple Window Display The EVC System Display instrument offers the possi- bility to view multiple windows with operating informa- tion simultaneously. The display has four different pages to choose from: ENGINE, MULTI, TRIP and GRAPH. The five buttons (1–5) on the front of the display are used to operate the four pages.
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Instruments and Controls Engine Page (Button 1) Enter the ENGINE page by pushing button 1. This page shows windows with engine speed, boat speed, and trip information. If information about boat speed is not available, coolant temperature is shown instead. If there is a tank sender installed, a fuel level gauge is shown in the trip window.
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Instruments and Controls MULTI Page (Button 2) Enter the MULTI page by pushing button 2. There are three window types available on the MULTI page: EVC Basic Window. For additional informa- tion, please see EVC Basic Window. Pointer Instrument Window Digital Number Window 51278 Alternate between these (or combinations of these)
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Instruments and Controls Trip Page (Button 3) Single engine installations Enter the TRIP page by pushing button 3. This display mode shows: ● TRIP FUEL – Total amount of fuel used since last time reset (l, Gal). ● TRIP RATE – Average fuel consumption since last time reset (l/h, Gal/h).
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Instruments and Controls Settings – EVC System Display Settings for the “EVC system display” are performed using the buttons (1–5) on the display. The engine(s) must have the ignition switched on when display settings are performed. Display Contrast Adjust the display contrast by pushing button 5. Then push the “contrast buttons”...
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Instruments and Controls Engine This setting is usually performed by the boat builder. Set which engines are connected to the display. Choices relevant to gasoline engine installations are SINGLE, PORT, STARBOARD, or TWIN (two engines to one display). 1. Enter the (hidden) CONFIGURATION MENU by 50869b pressing button 5 for 5 seconds (or more).
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Instruments and Controls Screens 7" Color Display The Volvo Penta 7" color display is controlled by means of buttons: Turn to browse through submenus and to return to the main menu, Select view. Return to the previous menu. Confirms selection; also used to access sub- menus and the Settings menu.
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Instruments and Controls My View Boat, engine and transmission data are displayed in My View as analog or digital instruments. Selection of instruments to be displayed and their appearance is made under the Customize menu. Information for up to three engines can be displayed on the same screen in boats with multiple engine instal- lations;...
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Instruments and Controls Removing Instruments Turn to the Remove menu and press Turn to the instrument that is to be removed and con- firm with P0001184 Changing Instruments Turn to the Modify menu and press Select the instrument that is to be changed and press Choose between: Remove, removes the instrument.
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Instruments and Controls Fuel economy This view functions as the boat's trip computer. Depending on the functions installed in the boat, the following can be displayed: Instant Fuel Rate, current fuel consumption per hour. Average Fuel Rate, average fuel consumption since the last trip computer zero reset.
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Instruments and Controls Vessel Information concerning boat installations is displayed in this view. Depending on the functions installed in the boat, the following can be displayed: - Sea Water Temperature - Depth, to set the echo sounder refer to Depth Alarm (Optional) in the EVC Menu section of this chapter.
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Instruments and Controls Settings Screen settings and different function settings are made in this view. Turn to the desired menu and press to access the submenus. Mode Choose between the modes Day (dark text on a white background) or Night (light text on a dark background). Press to switch between modes.
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Instruments and Controls Components, press to see installed compo- nents. Software, information regarding the software ID number. The following is only displayed if the function is instal- led. Speed Correction, setting the speed factor. Depth, setting the echo sounder depth alarm. Fol- low the instructions on the screen.
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Instruments and Controls EVC Menu Main Menu The main menu is the top level of information available in the EVC Basic Window. The Settings selection is always located in the main menu. You may or may not see the Settings selection when the system is first started.
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Instruments and Controls Retrieving Faults Faults set in the system during a trip can be viewed in the FAULTS MENU of the EVC Basic Window (the LCD display of the tachometer). The EVC Basic Win- dow is operated with buttons on the EVC Control Panel.
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● PTA – Allows the Power Trim Assistant to be turned on and off. 51448a ● Depth Alarm – Allows the depth alarm to be turned on and off. Optional Volvo Penta depth sounder (multisensor) required. 51465 ● Trip Reset – Allows all trip data (Trip Fuel Rate, Trip Fuel Econ, Trip Fuel, Trip Time, and Trip Distance) to be reset (zeroed out).
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Instruments and Controls ● Time To Empty – Displays time to empty fuel tank based on instantaneous fuel rate and remaining fuel (h). Optional fuel level sender con- nected to EVC required. 51472 ● Dist. To Empty – Displays distance to empty fuel tank based on instantaneous fuel rate, remaining fuel, and speed (nm, km, miles).
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NMEA 0183/NMEA 2000 compatible component (plotter, GPS, paddle wheel, etc.) required. 51486 ● Depth – Displays current depth of the water under the boat (ft, m). Optional Volvo Penta depth sounder (multisensor) required. 51487 ● Water Temp – Displays the temperature of the water surrounding the boat (°C, °F).
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Instruments and Controls Settings Menu In the Settings menu, you may set various options and calibrate various parameters for the EVC system. For twin engine installations always perform the set- tings on the port side system. Port side is the master side.
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Instruments and Controls Depth Alarm (Optional) If your boat is equipped with a Volvo Penta depth sounder (multisensor), you may perform the following settings. These settings need to be performed only on one display (twin installation) at one station for the settings to apply to all displays in the boat.
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Instruments and Controls Trip Reset The Trip Reset function (located within Settings) allows you to reset (zero out) all trip data that has been compiled and calculated. Trip data that will be reset includes trip fuel rate, trip fuel economy, trip fuel, trip time, and trip distance.
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Instruments and Controls Neutral Beep The neutral beep, a beep that indicates that the control levers are in neutral positions, can be turned on and off. This setting needs to be performed on each station in 51460 the boat. For twin installations: The setting only needs to be performed on either display on each station.
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Instruments and Controls Units The Units option allows you to select which units to display. These settings need to be performed only on one display (twin installation) at one station for the settings to apply to all displays in the boat. In the Settings menu, turn the SELECTION WHEEL to select Units.
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Instruments and Controls PTA Calibration The PTA (power trim assistant) adjusts trim angle automatically according to engine speed (RPM). It is possible to set five trim angles at five different engine speeds (including idle speed). For twin installations, the PTA CALIBRATION can be performed on either display (engine side). 1.
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If the Fuel Tank menu selection does not appear in the Settings menu, you will need to take your boat to an authorized Volvo Penta dealer. The dealer must perform fuel tank capacity and fuel tank empty calibrations.
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Multipoint Calibr., this pop-up will appear once every drive cycle when viewing trip data. 51692 Log Cal. Factor If your boat is equipped with a Volvo Penta speed sensor (multisensor), this setting needs to be per- formed. The log calibration (speed) factor for the boat’s paddle wheel speed sensor can be adjusted with a resolution of ±...
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Instruments and Controls 1. Move the control lever to the neutral position. 2. Navigate to the upper level menu and press the left < or right > arrow buttons until you locate the Neutral warm up screen. 51752 3. Press the OK button to change the neutral warm up function to On in the screen.
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1 . While Volvo Penta provides an engine status panel with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an engine status panel available, we strongly recommend that you contact your dealer to have one installed.
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Instruments and Controls Engine Status Warning The engine status warning or Malfunction Indicator Lamp (MIL) will provide you with visual and audible indications of any faults that may be occurring in the emission control system. This warning will be accom- panied by the buzzer.
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Instruments and Controls Power Trim Power Trim Power trim in an EVC installation is operated from the main or secondary station using the power trim buttons on the power trim control panel or on the con- trol lever(s). The position of the drive is shown on the trim instrument (digital or analog) or in the display(s).
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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°...
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Instruments and Controls Power Trim Instrument and Displays Digital Instrument The digital instrument shows the trim angle in digits and the trim range (TRIM) and beach range (BEACH) in letters. When in beach range the LED 1 lights orange. When in tilt range, the LED 2 lights red (no letters are displayed).
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Instruments and Controls Power Trim Assistant The power trim assistant (PTA) adjusts the trim angle automatically according to engine speed (RPM). PTA will not move the drive if it is manually trimmed above 7°. 51283a The PTA is turned on and off in the SETTINGS menu or in the main menu level if the option has been selected for viewing at that level.
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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.
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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.
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Instruments and Controls Enabling the Docking Function NOTICE! If you are using a cruise control system, it must be turned off before the joystick mode can be activated. A. Docking button (ON/OFF) B. Boost button (ON/OFF) Always push the buttons firmly and hold for at least one second.
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2. Two beeps indicate that the boost mode is dis- abled. The LED above the button goes out. The system is now in normal docking mode. Other Instruments See your Volvo Penta dealer for additional accessories specifically designed for your Volvo Penta product. 47700387 06-2009...
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Instruments and Controls Steering System Electronic Steering Control Unit Each engine uses a hydraulic valve body and a steer- ing control unit to control the movement of the drive during steering. Both devices are contained in a black housing A mounted somewhere in the engine com- partment.
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.
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● 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.
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.
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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.
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Starting Before Starting WARNING! To prevent a possible explosion hazard, operate the engine compartment bilge blower as recommended by the boat manufacturer before starting the engine. Do not operate the engine without a fully functioning bilge blower. ● Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, ensure that there is proper ventilation in order to remove exhaust gases from the area.
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Starting 4. Open the fuel cock B. Also, ensure that the sea cock is open–if so equipped. 51422 5. Make sure that there are no fuel, engine cool- ant, or oil leaks C. 21190-a 6. If your engine is equipped with a closed cooling system, check the reservoir for coolant level.
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ECM, the alarm will sound; otherwise, it will remain off. 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.
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Starting Carbureted Engines – When the ignition switch is turned to RUN (key on, engine off), the alarm emits a constant tone. The alarm remains operational until the key is either turned to OFF or the engine is started up. Starting Using the Start/Stop Panel Push the starter button.
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Starting Non-EVC Engines 1. Move the control handle to the NEUTRAL detent position N. 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.
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Starting Flooded Engine EVC Engines To clear a flooded engine: 1. Turn the key to ON I (RUN). 2. On the EVC control panel, press and hold the NEUTRAL BUTTON 3 while moving the control lever 2 forward to the shift position F. 3.
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Starting Non-EVC Engines To clear a flooded engine: 1. Advance the remote control lever to the FULL THROTTLE T position. NOTICE! Be prepared to quickly move the control handle to IDLE once the engine starts. This will avoid over-speeding and possibly damaging the engine.
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.
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Operation Reading the Instruments NOTICE! Check instruments regularly. Stop the engine if there is an abnormal reading or if the engine alarm sounds. NOTICE! If oil pressure is too low: Stop the engine immediately and investigate. Operating the engine with oil pressure too low will damage the engine.
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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.
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Operation Operating Trim Controls Control Panel The control panel has two standard buttons for tilt con- trol: ● The top button moves the drive trim out while raising the boat’s bow. ● The lower button moves the drive trim in while lowering the boat’s bow.
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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”...
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“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. 47700387 06-2009...
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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.
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Operation Cruising Speed Volvo Penta recommends the cruising speeds in the Engine Max Cruising RPM chart at left (based on 75% of maximum RPM at wide 3.0GXi 3300-3600 open throttle (WOT)). Operating the engine at WOT for 5.0GXi 3450-3750 extended periods should be avoided since it is both 5.7Gi-300...
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Operation Single Control Lever Operation Both the gear shift release and engine speed control are operated using the single lever 2. N Neutral position (drive is disengaged and the engine runs at idle speed). F Drive/forward gear engaged for forward move- ment (ahead).
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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...
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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.
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Operation Neutral Interlock Button The neutral interlock button 1, available on the side- mount control only, prevents accidentally moving the throttle out of neutral. This button must be depressed to shift the throttle out of neutral. To move the control lever away from neutral: 1.
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Operation Changing and Activating Station The gear must be in neutral when changing stations. The LED above the NEUTRAL BUTTON 3 is lit when the gear is in neutral (both are lit for twin engines). If the station that you want to leave is locked, unlock it (please see next page).
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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.
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Operation Steering with Control Levers Rotating the Boat NOTICE! Do not use this procedure if steering faults exist on one or both drives. This procedure requires that both sets of engines and drives are in working order. Move one control lever into forward gear and the other control lever into reverse gear.
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Operation Loss of Steering NOTE! The following procedures only apply if the boat is equipped with electronic or joystick steering. WARNING! When steering wheel control is lost, engine speed is automatically limited. WARNING! When one engine stops running, oil pressure needed to control steering for that drive side will be lost. While the functioning side will still provide steerage, control characteristics for the boat will be substantially different from that of two running engines.
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Operation Steering System Fault Messages If a malfunction in the steering system is discovered, a steering specific pop-up will appear in the tachome- ter or system display. The audible warning may also sound. If installed, a relevant warning lamp will start to flash on the alarm panel.
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Operation Maneuvering with the Joystick DANGER! A rotating propeller can cause serious injury. Ensure that there is no one in the water before you enable docking mode. Never go near people who are swimming or where there is a risk that there are people in the water. NOTICE! Remember that the side thrust is considerably greater than with a conventional bow thruster.
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● 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. 47700387 06-2009...
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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 ●...
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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.
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.
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Engine Shutdown Stopping Using the Start/Stop Panel Push the stop button. Release the button when the engine has stopped. Use both buttons for twin engines. If a station is active and locked, the engine(s) can only be stopped from that station. 51273 47700387 06-2009...
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Engines or Draining Raw Water Side of Closed Cooling System Engines. 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.
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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.
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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.
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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.
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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 engine.
Fault Code Register CAUTION! Read the safety precautions for maintenance and service in the Safety Information chapter before starting work. The following are descriptions of potential faults, the warning lamp (and its color) that may be activated, an indication of whether the audible alarm will sound, and the associated pop-up that will appear on the EVC tach- ometer display.
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Operator Action: AMBER ● Check battery fluid level. ● Check belt tension. ● Contact a Volvo Penta dealer if the fault persists. Check Control Lever Symptom: Fault in throttle control lever. EVC Action: Depends on severity of fault–red or amber lamp.
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● Restart engine(s). ● If the engine cannot be operated from the chosen con- trol panel, use an alternative control panel. ● Contact a Volvo Penta dealer. Check Joystick Symptom: Fault in joystick. EVC Action: Engine power is reduced.
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● If the cooling water flow ceases, the exhaust hose should be inspected internally and replaced if the hose shows signs of damage. ● Contact a Volvo Penta dealer if the fault persists. Engine Oil Press. Symptom: Engine oil pressure too low.
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Operator Action: ● Check that the seawater intake is clear. ● Check the impeller in the seawater pump. ● Check exhaust hoses. ● Contact a Volvo Penta dealer if the fault persists. Fuel Pump Relay Symptom: Faulty relay. AMBER –...
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● Check circuit breakers/relays. ● Check for loose electrical connections. ● Check battery condition. ● Check for kinked hoses. ● Contact a Volvo Penta dealer. No Gear/Throttle, No Steering Symptom: Helm computers lose communications with both drivelines. EVC Action: Engine RPM reduced to idle. Gears are shifted to neutral.
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Operator Action: ● Check ignition relay in fuse box and replace if neces- sary. ● Contact a Volvo Penta dealer if the fault persists. Power Trim Faults Symptom: Fault in power trim system. Possibility that the system does not detect relays or trim sensor drifts without operator action.
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EVC Action: None. Operator Action: ● Check battery condition. ● Check for loose battery cables. ● If possible and if necessary, switch battery selector to “ALL” and use house batteries. ● Contact a Volvo Penta dealer if the fault persists. 47700387 06-2009...
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.
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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.
● 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.
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● 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.
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● 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.
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● 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.
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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. 47700387 06-2009...
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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.
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If the problem continues, contact your Volvo Penta dealer and have the engine inspected. 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.
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See the next section for additional infor- mation. If the problem persists, contact your Volvo Penta dealer and have the engine inspected. 47700387 06-2009...
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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. Water in Bellows OceanX (OXi) drives are equipped with a sensor that detects water intrusion in the bellows.
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Troubleshooting If the alarm persists after checking the oil level and quality, please contact your dealer for repairs as soon as possible. Oil Sensor Reset Whenever the drive oil is replaced, the drive oil sensor must be reset. If your dealer changed the oil in the drive, the sensor should already have been reset.
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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.
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● 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.
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Troubleshooting EVC Diagnostic Function Despite regular maintenance (in accordance with the maintenance schedule) and perfect operation, faults may occur which must be addressed before the boat can be operated any further. This chapter describes the purpose of the EVC’s diagnostic function, the types of alarms and messages the operator can get from the EVC system, and how to address problems when they occur.
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Troubleshooting Alarm for Fuel or Depth (Optional) These alarms appear as a “fuel left in %” or “depth in m/ft” pop-ups that alternate between “data symbol” and “warning triangle.” The depth alarm pop-up is also accompanied by a buzzer. The fuel level alarm pop-up will appear when the fuel level is lower than fuel alarm setpoint.
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Troubleshooting Warning Signals Engine Reduced Forced Shuts Required Operator Response Throttle Idle Down Engine and/or emission system should be inspected by authorized service technician at your earliest convenience Engine and/or emission system should be inspected by authorized service technician at your earliest convenience Even at full throttle, boat may not reach planing speed;...
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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.
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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).
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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.
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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.
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.
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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 ●...
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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.
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4) Engine oil change interval can be increased to 200 hours if full synthetic oil is used, see Scheduled Oil Service in 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. 47700387 06-2009...
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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;...
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.
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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.
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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.
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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.
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● 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. 47700387 06-2009...
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(5.3 mm) and/or the length is less than 7/16 in. (11.3 mm), be sure to have the exhaust system inspected at a Volvo Penta dealer at your earliest con- venience. Be sure that new anodes are installed to replace the old.
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Maintenance Anodes (3.0L Engines) 3.0L engines use the following anodes (installed in the locations indicated): 1. Anode – Requires 10mm Allen wrench or 5/8 in. socket to remove. 2. Reference Anode – Marked blue. Check at least once per season or whenever you drain the raw water system.
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51427 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. NOTICE! Failure to periodically check engine align- ment may result in premature failure of the engine cou- pler.
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Maintenance Fuel System 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.
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Maintenance Cooling System NOTICE! Do not run the engine without the thermostat as the engine is likely to overheat. Replacing the Engine Thermostat For instructions on replacing the engine thermostat on closed cooling engines, please see the Do It Your- self manual.
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Maintenance 8.1 Liter Engines (Raw Water Cooled) 1. Loosen and remove long bolt 1, washer 2, and short bolt 3; save for reuse. 2. Remove thermostat housing 4. 3. Remove thermostat 5, small O-ring 6, and large O-ring 7, from cross-over pipe housing 8. Discard thermostat.
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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.
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Maintenance NOTICE! Do not disconnect the batteries with the engine running as sensitive electrical components may be immediately damaged. NOTICE! Do not use wing nuts to secure battery cables, even if they were supplied with the battery; use a lock nut instead. NOTICE! Some maintenance-free batteries have spe- cial care instructions.
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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 47700387 06-2009...
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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.
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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.
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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...
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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.
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.
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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.
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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;...
Calibration and Settings This section contains instructions for configuring EVC and EVC system display settings. NOTICE! If using a Volvo Penta fuel level sensor and/ or multisensor, ensure that fuel tank calibration and depth alarm settings are performed correctly before starting to operate the boat for the first time.
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Calibration and Settings Calibrating the Joystick Function This calibration only needs to be performed if the boat movement does not correspond to the movements of the joystick. Calibration only needs to be done in one direction, port or starboard. CAUTION! When calibrating the joystick function the boat must be operated in open water and under safe conditions.
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. 47700387 06-2009...
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143°F (62°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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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These oils are available at Volvo Penta deal- ers. If the Volvo Penta oils are not available, use high qual- ity oil that meets API SM and/or ILSAC GF-4 specifi- cations. Viscosity should be SAE 10W30 or higher (example: 10W30, 10W40, 15W50).
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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.
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NOTICE! Mineral oil is required for the first 150 hours or three years, whichever occurs first. After the first 150 hours or three years, synthetic oil can be used in the engine. If Volvo Penta synthetic oil for gasoline engines is used, the change interval is every year or every 200 hours, whichever occurs first. When an engine has been run on synthetic oil, our recommendation is to continue with synthetic oil;...
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22823 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.
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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.
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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...
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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.
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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)
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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.
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Technical Data The tune-up and color code decal is located on the engine cover. 22775 47700387 06-2009...
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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.
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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 47700387 06-2009...
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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...
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5.0 Litre NOTICE! This Declaration of Conformity does not apply to boats using through-hull exhaust systems. 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...
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5.7 Litre NOTICE! This Declaration of Conformity does not apply to boats using through-hull exhaust systems. 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...
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8.1 Litre NOTICE! This Declaration of Conformity does not apply to boats using through-hull exhaust systems. 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...
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Volvo Action Service (VAS)........12 Pitot Tube (Speedometer Port)......152 Volvo Penta Dealer Network........13 Power Steering Reservoir Fluid Level....155 Volvo Penta on the Internet........13 Power Tilt Operation..........97 Power Trim Assistant..........58 Power Trim Buttons..........55 Power Trim Instrument and Displays...... 57 Power Trim/Tilt............
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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: 47700387 Name: Address: Country: E-mail: English Dansk Svenska Soumi Deutsch Português Français Ελληνικά Español Русско...
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