Page 1 OPERATOR’S MANUAL 4.3L, 5.0L, 5.7L SX-A, DPS-A...
Page 2 Copyright © 2010 Volvo Penta of the Americas. 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...
Page 3: Table Of Contents
Content Foreword ...................... 2 Safety Information ..................4 Introduction ....................12 Instruments and Controls ................ 14 Optional ..................... 59 Starting ...................... 61 Operation ....................68 Engine Shutdown ..................90 Fault Code Register .................. 96 In Case of Emergency ................104 Troubleshooting ..................
Page 4: Foreword
Foreword Models This manual applies to the following engines: Engine Model Spec. No. Displacement 4.3L 4.3GXiE-Q 40869311 5.0L 5.0GXiE-P 40869295 5.7GiE-300-P 40869296 5.7L 5.7GXiE-P 40869297 NOTICE! Throughout this manual, whenever model-specific information is provided, the text will be preceded by the model designation of the engine being discussed.
Page 5 Volvo Penta product. Volvo Penta continually commits a considerable part As an owner of a Volvo Penta marine engine, we of its development resources toward minimizing the would also like to welcome you to a worldwide net- environmental impact of its products.
Page 6: Safety Information
If you do not understand or are uncertain about any operation or information in this owner’s manual, please contact your Volvo Penta dealer. Your dealer will be able to help you with an explanation or will demonstrate the operation. Federal law requires manufacturers to notify owners in the event that a safety related defect is discovered on any of their products.
Page 7 Safety Information Maintenance Performing maintenance on the engine can be a dangerous undertaking. We strongly recommend that you con- sult your dealer. Find the correct information in the following publications: this operator’s manual, any applicable Do it Yourself manual, and any applicable workshop manuals. Engine Decals Check that the warning decals on the engine are always clearly visible.
Page 8 Safety Information Serpentine Belt and Pulley System CAUTION! Working around the serpentine belt and pulley system can be dangerous. To prevent possible injury caused by pinching, crushing or entanglement, always observe these precautionary measure when working around the engine: ● Ensure that the engine cannot be started by removing the ignition keys from each starting location. This hazard is especially likely to occur if the engine room or engine compartment cannot be seen from various remote starting positions such as a flybridge or enclosed cabin.
Page 9 Safety Information Carbon Monoxide DANGER! Do not run the engine while there are people located on or near the swim platform and transom. DANGER! Do not tow anyone using water sports equipment (such as skis and inner tubes) closer than twenty feet (6 meters) from the boat.
Page 10 Safety Information How is a Person Affected by Carbon Monoxide? Carbon monoxide is absorbed by the lungs and reacts with blood hemoglobin to form carboxyhemoglobin, which reduces the oxygen carrying capacity of the blood. The result is a lack of oxygen for the tissues, with subsequent tissue death and, if exposure is prolonged, death of the individual.
Page 11 Safety Information Stationary Operation A boat operator should be aware that dangerous con- centrations of CO can accumulate when propulsion engines and/or an auxiliary generator is operated while the boat is stationary. This is especially true when rafted or moored in a confined area such as boat- houses, or when in close proximity to seawalls or other boats.
Page 12 Safety Information Underway Operation Do not sit on, occupy or hang on any stern appendages (e.g., swim platforms, boarding ladders, etc.) while underway. Do not body surf, commonly known as “teak surfing” or “platform dragging,” in the wake of the boat. Do not tow persons in close proximity to the stern of the boat.
Page 13 Refer to the Maintenance Schedule and Main- tenance sections of this manual for instructions on keeping your engine and sterndrive in good condition. NOTICE! Be sure to see your Volvo Penta dealer for regular inspections. 47701898 12-2010...
Page 14: Introduction
Penta. Your dealer should provide you with proof of ownership in the form of an Owner's Registration Card or a print-out of the Volvo Penta computer on-line reg- istration screen. This provides proof of ownership and is required to validate warranty, should warranty serv- ice become necessary.
Page 15 Volvo Penta dealer, Volvo Penta on the Internet is the web site to visit. Additionally, you will find a wealth of infor- mation related to our company and all the new and innovative products we have to offer.
Page 16: Instruments And Controls
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.
Page 17 Instrument panels can also be supplemented with extra Volvo Penta instruments such as: synchronization tach- ometers, fuel gauge, fresh water gauge, clock, speedometer, or rudder indicator.
Page 18 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.
Page 19 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.
Page 20 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.
Page 21 Instruments and Controls Docking Station Panel The docking station is comprised of a joystick and a docking panel dedicated solely for docking the boat. Directions for using the joystick are provided in the sections entitled Controls and Operation. The docking panel allows station activation/deactiva- tion, stopping and restarting of the engines, and con- trast/backlighting control while operating the boat from a docking station.
Page 22 Instruments and Controls Alarm Acknowledge Button Fault messages are displayed on the screen when the system discovers a fault. All fault messages must be acknowledged. Acknowledge by pressing the far right button; if the fault is accompanied by an audible signal, the signal will be silenced.
Page 23 Instruments and Controls EVC System Display There are four types of displays. When using a top mount remote control, you must have either the Info Display Panel or the Color Display installed. For a single side mount remote control, you are not required to have a display installed.
Page 24 Instruments and Controls EVC Basic Window While the EVC System Tachometer displays only engine hours, the EVC System Display provides a vari- ety of operating information that can be monitored simultaneously. The EVC System Display is operated with buttons on the display panel.
Page 25 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.
Page 26 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.
Page 27 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)
Page 28 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).
Page 29 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.
Page 30 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;...
Page 31 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.
Page 32 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.
Page 33 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.
Page 34 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.
Page 35 Instruments and Controls Gauge Range, setting instrument maximum display range. Boat Speed, 10 – 100 knots, in steps of 10 knots. Engine Speed, 2500/3000/4000/5000/6000 rpm. Propeller Speed, 1000/2000/3000 rpm. EVC Information, this information cannot be changed. Features, installed functions are marked blue. Components, press to see installed compo- nents.
Page 36 Instruments and Controls EVC Menu Navigation The Info Display Panel provides engine and opera- tional information, messages, and alarms. There is one information panel per driveline and helm station if no 7" screen is installed. The information shown can be set up according to per- sonal preferences.
Page 37 Instruments and Controls Main Menu The main menu is the top level of information available in the Info Display 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. The last screen displayed before engine shutdown will be the first screen displayed when the system is restarted.
Page 38 EVC required. ● Depth Alarm – Allows the depth alarm to be ● Fuel Economy – Displays instantaneous fuel turned on and off. Optional Volvo Penta depth rate per distance (nm/l, km/l, mile/l, nm/gal, km/ sounder (multisensor) required.
Page 39 ● Propeller RPM ● Depth – Displays current depth of the water Not used on gas engines under the boat (ft, m). Optional Volvo Penta depth sounder (multisensor) required. ● Engine RPM – Displays engine speed in revolu- ● Water Temp – Displays the temperature of the tions per minute (rpm).
Page 40 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.
Page 41 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.
Page 42 Instruments and Controls Display Contrast The display contrast can be adjusted in increments of 10% between 0–100%. This setting only applies to the display in the EVC Info Display. Each display in the boat is set separately. In the Settings menu, scroll to select Display Contrast. Press the OK button to enter the display contrast set- tings.
Page 43 Instruments and Controls Language The displays can show information in 10 different lan- guages. This setting needs 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, scroll to select Language.
Page 44 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.
Page 45 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.
Page 46 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 ±...
Page 47 Instruments and Controls Thottle Only The gear shift can be disengaged so that the control lever affects only the engine speed. To disengage the shift from gear, move the control lever to the neutral position, press the Throttle Only button 13, then move the throttle control into—or past—idle.
Page 48 Instruments and Controls Tow Mode Tow mode is a simple speed (engine RPM) control function that helps maintain a steady acceleration and a constant velocity when wake boarding or water skiing. NOTICE! Tow Mode is only applicable for single engine installations with a single helm. NOTICE! Tow Mode cannot be used via the 7”...
Page 49 Instruments and Controls Crank Override Mode If the drive is in tilt range and the engine must be started, you may do so by using Crank Override Mode. When you first try to start the engine with the drives in the tilt range, you will receive a message that the engine cannot be started and that trim is too high.
Page 50 Instruments and Controls Power Trim Buttons The buttons on the power trim control panel are used for both single and twin engine installations. By trimming out the drive away from the transom, the height of the bow will be “raised” in relation to the hor- izontal axis, while trimming in the drive will “lower”...
Page 51 Instruments and Controls Power Trim panel The Power Trim panel allows you to adjust the angle of the drive with respect to the transom. For twin engine installations, the power trim panel may be used to make individual or simultaneous adjustments to the drives.
Page 52 Instruments and Controls Trim Ranges In order to utilize the information gained from the trim instrument, it is essential to know about the different trim ranges and their uses. There are three trim ranges as described below. Trim Range Trim range, for a drive with a single prop, is any angle between -5°...
Page 53 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).
Page 54 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.
Page 55 Instruments and Controls Emergency Trimming If a fault occurs which prevents the drive from being trimmed with the power trim control panel, it is possible to perform an emergency trimming. You may do so by holding the trim up/out button on the remote control (A or 10) for over 5 seconds.
Page 56 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 con- trols. 51812 51814 51813 1.
Page 57 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 remote control and you wish to make adjustments to the friction brake, follow the instructions below to make the necessary changes.
Page 58 Instruments and Controls Enabling the Docking Function A. Docking button (ON/OFF) B. Boost button (ON/OFF) Always push the buttons firmly and hold for at least one second. Follow the instructions below when you wish to enable the docking function on the main or flybridge station. The docking function is automatically enabled on the docking station when it is activated.
Page 59 Instruments and Controls Disabling the Docking Function The docking function can be quickly disabled. NOTICE! If the docking function is disabled, the boat cannot be maneuvered with the joystick. 1. Push the docking button A on the joystick or move the control levers out of neutral. The docking function is disabled automati- cally if the control levers are moved from neutral.
Page 60 Instruments and Controls Other Instruments See your Volvo Penta dealer for additional accessories specifically designed for your Volvo Penta product. 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.
Page 61: Optional
Active Corrosion Protection System Your boat may be equipped with a Volvo Penta active corrosion protection system (APCS). This system operates with very little current drain from the boat’s electrical system. It keeps the voltage potential in the area around the drive unit in a range that is not corrosive to aluminum.
Page 62 ● Broken anode or reference sensor unit. Replace damaged unit. Follow the installation instructions included with the replacement unit, or see your authorized Volvo Penta dealer for service. If any of the malfunction conditions continue to exist after completing the steps above, see your authorized Volvo Penta dealer for further service.
Page 63: Starting
Starting Static Water Line Static water line is a measurement of the water level in the boat engine's exhaust system. The exhaust pas- sages of a sterndrive propulsion system are open to the water surrounding the boat A. When the engine is not running, the water level in the exhaust system will settle at the same level as the surrounding water B.
Page 64 3. Bring plugged end of hose inside the hull C 6. If the static water line does not meet these and hold next to–and above–the manifold B. specifications, contact your Volvo Penta dealer for information on high rise extension kits. Make sure one is installed before the engine is started for the first time.
Page 65 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.
Page 66 Starting 3. Check the bilge for excessive water accumula- tion. Always keep the bilge clean and dry. NOTICE! The water level in the boat’s bilge will increase when you operate your boat at a high incline before you reach planing speed. Exces- sive water in the bilge can cause engine dam- age.
Page 67 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.
Page 68 Starting Starting Using the Start/Stop Panel Press the starter button for each engine. Release the button as soon as the engine has started. If you start from a secondary station, the starter key at the main control station must be in the ignition ON engine OFF position.
Page 69 Starting Flooded Engine To clear a flooded engine: 1. Turn the key to ON I (RUN). 2. On the single side mount remote control, press and release the Throttle Only (N) button A, then move the control lever forward to the shift posi- tion.
Page 70: Operation
Volvo Penta. If you have non Volvo Penta equipment installed on your boat or if the Volvo Penta equipment installed is not covered in this manual, please refer to any additional documentation that came with your boat.
Page 71 For a detailed explanation of the problems mentioned above and the steps to take to deal with them, please refer to the chapter entitled Troubleshooting. 3. While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an audible alarm available, we strongly recom- mend that you contact your dealer to have one installed.
Page 72 Operation Maneuvering Power Trim/Tilt Your Volvo Penta sterndrive is equipped with a power trim/tilt system as standard equipment. The power trim/tilt allows you to change the angle of the drive unit from the helm. Changing the angle of the drive unit in relation to the boat bottom is called trimming.
Page 73 Operation Determining the Proper Trim The effect of the maximum “bow-up” and “bow-down” positions will be similar for most boats. The bow posi- tion best for your operating conditions could be at any trim setting between the maximum “bow-up” and “bow- down”...
Page 74 “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. 47701898 12-2010...
Page 75 If there is damage, operate the boat at low RPM and 50406 take it to a Volvo Penta dealer for inspection. Operating a damaged unit could cause additional damage and could become very costly to repair. Have necessary repairs made immediately. Only operate your boat if absolutely necessary.
Page 76 Operation Cruising Speed Volvo Penta recommends the cruising speeds in the chart at left, based on 75% of maximum RPM at wide open throttle (WOT). Operating the engine at WOT for extended periods should be avoided since it is both uneconomical and reduces engine life.
Page 77 Operation Single Control Lever Operation Both the gear shift release and engine speed control are operated using the single lever 3. N Neutral position (drive is disengaged and the engine runs at idle speed). F Drive/forward gear engaged for forward move- ment (ahead).
Page 78 If you suspect there is a problem, see your Volvo Penta dealer as soon as possible for proper diagnosis and required service or adjustment. Continued operation...
Page 79 Operation Twin Unit Maneuvering When leaving or approaching the dock, or for any close maneuvering at slow speed, place the port engine con- trol lever 3 in neutral N (on standby) and use the star- board engine. The use of one control is very effective and more convenient.
Page 80 Operation Neutral Interlock Button The neutral interlock button 2, 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.
Page 81 Operation Station Handling Active Station Shifting, adjusting speed, trimming, and performing EVC settings and calibrations is only possible on an active station. On a boat with one station, the station is always active. On a boat with two or more stations, the main station automatically becomes active when the EVC system is started up with the ignition key(s).
Page 82 You will be able to steer the boat, but with increased effort. See your authorized Volvo Penta dealer as soon as possible to correct your power steering system. At slow speeds (no wake), your boat may tend to wan- der due to wind and current.
Page 83 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.
Page 84 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.
Page 85 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.
Page 86 Operation Steering System General Messages Low Steering Oil Temperature For the electronic steering to operate normally, the oil must reach a certain temperature. When the oil is cold, steering is slower than normal. This condition is espe- cially true in colder climates. The system displays a message to let you know when the temperature is too 51650 low.
Page 87 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.
Page 88 Operation 51318 51319 51320 47701898 12-2010...
Page 89 ● 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. 47701898 12-2010...
Page 90 NOTICE! Freeze damage to the engine package is not covered by your Volvo Penta limited warranty. Upon completion of engine operation, drain the engine as described in Draining the Engine in the chapter enti- 21199 tled Engine Shutdown.
Page 91 Volvo Penta Limited Warranty. 22799 Salt Water Operation You can use your Volvo Penta sterndrive in either fresh or salt water. We recommend that you use fresh water to flush out the engine and drive after you use your boat in polluted or salt water.
Page 92: Engine Shutdown
Engine Shutdown Before Engine Shutdown WARNING! Never abruptly change speed. Sudden changes in speed may cause passengers to be thrown about in the boat. Power Tilt Operation Tilting is normally used for raising the drive unit to obtain clearance when beaching or launching from a trailer.
Page 93 Engine Shutdown Stopping Using the Start/Stop Panel Push the stop button for each engine. Release the but- ton when the engine has stopped. If a station is active and locked, the engine(s) can only be stopped from that station. 47701898 12-2010...
Page 94 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.
Page 95 Engine Shutdown Trailering Your Boat 1. Before loading your boat on the trailer, tilt the drive unit up. 2. After your boat is on the trailer, completely lower the drive unit until the drive drains thoroughly. 3. Rinse the entire drive exterior with fresh water. NOTICE! Before moving the trailer, tilt the drive as high as possible and secure it in place.
Page 96 Engine Shutdown Draining the Engine Draining Raw Water Cooled Engines 1. With the engine turned off, locate and open all drains located on both sides of the engine. Raw water drains are blue, hardened plastic plugs. NOTICE! Be sure that all water is drained from the engine.
Page 97 Engine Shutdown Draining Raw Water Side of Closed Cooling System Engines 1. With the engine turned off, locate and open all drains located on the manifolds on both sides of the engine. Do not drain engine block! NOTICE! Be sure that all water is drained from the manifolds.
Page 98: Fault Code Register
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.
Page 99 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.
Page 100 ● 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.
Page 101 ● 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.
Page 102 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 –...
Page 103 ● 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.
Page 104 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.
Page 105 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. 47701898 12-2010...
Page 106: In Case Of Emergency
Lift the boat ashore. Check the drive oil level and qual- ity. If the oil is milky-white, water has entered the drive and it must be inspected by an authorized Volvo Penta workshop. Replace the propeller if it is damaged.
Page 107 In Case of Emergency 1. Check that the auxiliary battery has the same voltage as the engine system voltage. 2. Connect the red positive cable to the plus (+) ter- minal on the discharged battery and then to the plus terminal on the auxiliary battery. 3.
Page 108: Troubleshooting
● Did the trouble occur suddenly or did it become apparent gradually? Whether servicing the boat’s systems yourself or having your product serviced by a certified Volvo Penta dealer, you will need this record of information to identify potential causes of the malfunction.
Page 109 ● Secondary circuit wiring, from coil to spark plug. ● Spark plugs–for proper gap, fouling, burned electrodes, or cracked/dirty insulator. ● Low battery voltage. ● Call for assistance or see Volvo Penta authorized dealer. Fuel System – Check: ● Fuel level.
Page 110 ● Fuel pump pressure. ● Water or contaminants in fuel. ● Manifold vacuum leak. ● Call for assistance or see Volvo Penta authorized dealer. If At High Speed – Check: ● Air leak on suction side of fuel system. ● Too low octane fuel.
Page 111 ● Water leaks on pressure side of supply pump. ● If equipped with a heat exchanger, check to be sure that it is free of debris. ● Call for assistance or see Volvo Penta authorized dealer. Engine Dies Out ● Refer to the section entitled Engine Protection Mode.
Page 112 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. 47701898 12-2010...
Page 113 A great number of environmental factors, such as baro- metric pressure, ambient temperature, humidity, the quality of fuel, and exhaust back pressure can affect engine performance. All Volvo Penta engines are tested and certified using the following fixed values or common conditions for determining the rating of the engine.
Page 114 If the problem continues, contact your Volvo Penta dealer and have the engine inspected. 4. While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an audible alarm available, we strongly recom- mend that you contact your dealer to have one installed.
Page 115 See the next section for additional infor- mation. If the problem persists, contact your Volvo Penta dealer and have the engine inspected. 47701898 12-2010...
Page 116 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.
Page 117 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.
Page 118 If a pump does not function, check the fuses and replace them if necessary. See your Volvo Penta dealer if further service is required. NOTICE! A loud whining noise at idle may be due to a restricted fuel filter causing a noisy fuel pump. Oper- ating the engine with a restricted filter may damage the pressure regulator or fuel pumps.
Page 119 ● Replace any blown fuses. NOTICE! Circuit breakers or fuses that repeatedly fail indicate a problem that requires immediate attention. See your Volvo Penta dealer. Fuse and Relay Box Layout Several spare fuses and relays are located on the inside of the fuse and relay box cover. In case of malfunctioning or faulty fuses and relays, use the spares provided.
Page 120 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.
Page 121 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.
Page 122 2. Make sure remote control is in NEUTRAL. 3. Coat full length of prop shaft and inside of prop hub with Volvo Penta prop shaft grease; removal of prop will be difficult if this is not done. 4. Ensure thrust bushing 1 is on prop shaft with inner taper toward gearcase to match taper on prop shaft.
Page 123 Troubleshooting Removing the DPS-A Propeller NOTICE! This “get home” (emergency) procedure will Special tool P/N 3862797 is needed to remove the require you to have tools and spare prop(s) and nuts front propeller nut on DPS-A drives. on hand. 1. Turn ignition switch to RUN (key on, engine off). 2.
Page 124 Troubleshooting Installing the DPS-A Propeller NOTICE! Failure to install all components could result in loss of the propeller and damage to the drive unit the next time the boat is operated. 1. Turn ignition switch off and remove key. 2. Coat the full length of both shafts with grease (P/N 828250).
Page 125 Engine Submersion 1. Remove the engine from the water as quickly as possible. 2. Contact your local Volvo Penta dealer for service. ● Your dealer will need to drain all water from the engine and immediately lubricate all internal parts.
Page 126 Troubleshooting Steering If you experience difficulty steering the boat, check for the following possible problems: ● Check the fluid level in the power steering pump reservoir. The level must be between the “Min” and “Max” lines. ● Check that all hose clamps on the power steering system are securely tightened.
Page 127: Maintenance Schedule
If emission control system repair is required during the warranty period, you are responsible for presenting your sterndrive engine to a Volvo Penta authorized dealer as soon as the problem exists. The warranty repairs will be completed using genuine Volvo Penta parts in a reasonable period of time without charge. After expiration of the emission control system warranty, you may present your sterndrive engine to a repair shop or person of your choosing to maintain, replace, or repair emission control devices and systems.
Page 128 Maintenance Schedule Owner's Checklist Check/ Fill/ Adjust/ Change/ Check Before Each Use Clean Correct Lube Tighten Replace Engine Cooling System – Check coolant level ; check ● ● system for leaks Engine Oil ● ● Fuel Pump and System – Check for leaks ●...
Page 129 See Technical Data. In markets outside the United States: All service specified by the maintenance schedules for the first year must be performed and documented by an authorized Volvo Penta dealer to be eligible for the Extended Pro- tection Service Plan.
Page 130 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. 47701898 12-2010...
Page 131 Maintenance Schedule Annual Service or Every 100 Hours Check/ Fill/ Adjust/ Change/ Clean (Continued) Correct Lube Tighten Replace Sterndrive Anodes – Visual inspection; replace if eroded more ● than 30% Bellows, U-joint, and Exhaust – Check for wear, ● ● damage;...
Page 132: Maintenance
If you are uncertain about any procedures described in the manual or you would like to purchase a workshop or Do it Yourself manual, please contact your Volvo Penta dealer or visit Volvo Penta on the Internet. Keep in mind, however, that there are certain tasks which should only be performed by your Volvo Penta dealer.
Page 133 We recommend that all servicing with the engine running be undertaken by an authorized Volvo Penta workshop. Starting the Engine After Service Reinstall all protective parts removed during service operations before starting the engine.
Page 134 Maintenance Batteries Incorrect connection of the battery can cause a spark, which would be sufficient to cause an explosion. Do not disturb battery connections when starting the engine (spark risk) and do not lean over batteries. Always ensure that the positive and negative battery leads are correctly installed on the corresponding ter- minal posts.
Page 135 Otherwise the general instructions contained in this Operator’s Manual concerning operation, service, and main- tenance must be followed. NOTICE! Late or inadequate maintenance/service or the use of spare parts other than Volvo Penta original spare parts will invalidate Volvo Penta’s responsibility for the engine specification being in accordance with the certified variant.
Page 136 ● 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. 47701898 12-2010...
Page 137 Do not paint ano- des, as this will destroy their effectiveness. When you need to purchase new anodes, see your Volvo Penta dealer. The material composition of Volvo Penta anodes meets U.S. Military Specification 18001-H. Some after-market anodes may not meet mil-specs.
Page 138 Maintenance 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.
Page 139 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.
Page 140 Maintenance Fuel Storage If the boat will not be used for two months or longer, the boat and engine must be prepared for this storage period. Both the fuel in the tank(s) and the engine must be treated. The fuel must be treated with fuel stabilizer. Add stabilizer according to the manufacturer's instructions.
Page 141 Maintenance Cooling System NOTICE! Do not run the engine without the thermostat as the engine is likely to overheat. For instructions on replacing the engine thermostat on closed cooling engines, please see the Do It Yourself manual. Replacing the Engine Thermostat For instructions on replacing the engine thermostat on closed cooling engines, please see the Do It Your- self manual.
Page 142 50/50 mix of silicate-based ethylene glycol coolant (typically green in color) and distilled water. Do not use other coolant types such as: Volvo Penta “VCS” coolant (yellow color), Propylene Glycol, or OAT and HOAT coolants. 51806...
Page 143 Maintenance Electrical System Battery Maintenance and Replacement DANGER! Never allow an open flame or electric sparks near the battery or batteries. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which, when mixed with air, can form an explosive gas.
Page 144 Maintenance Spark Plugs Your engine comes equipped with high quality spark plugs that require infrequent maintenance. Please see Maintenance Schedule for replacement frequency. WARNING! 23172-e Ensure that plug wires are in good condition to avoid sparking. Sparking could potentially cause a fire or explosion.
Page 145 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 47701898 12-2010...
Page 146 Maintenance Pitot Tube (Speedometer Port) The pitot tube, located at the leading edge of the lower unit, provides pressure input for the speedometer. If the pitot tube becomes clogged (e.g. the boat runs aground or the sterndrive drags through silt as the boat is loaded onto the trailer), the speedometer may stop functioning.
Page 147 Follow equipment manufacturers rec- ommendations. Anode Replacement Information NOTICE! Your Volvo Penta product has been shipped with Aluminum anodes. The table below provides replace- ment information and also specifies which anodes should be used, depending on water conditions. Anode Material Part No.
Page 148 Painting the Drive The sterndrive and transom shield require a unique paint repair procedure. Please refer to the Do it Your- self manual or see your Volvo Penta dealer for addi- tional information regarding painting the drive. Anti-fouling Paint: Drive and Transom...
Page 149 The fluid level must be above the “Min” line and below the “Max” line. If needed, add Volvo Penta Power Trim/Tilt and Steering Fluid. Do not overfill the pump reservoir. NOTICE! Never fill the steering system with oil of unknown quality.
Page 150: Storage
Storage Laying Up (Winterization) Be sure that your Volvo Penta equipment is properly prepared for long or short term storage. Engine or drive damage can result if some simple maintenance steps are overlooked prior to storage. Winterizing gives you the assurance that your engine will be protected during storage and will run more reliably when you put your boat back in the water.
Page 151 Storage Long Term Storage For long term storage (more than two months), we recommend that you have your Volvo Penta dealer “winterize” your engine and drive. Your dealer will provide the proper servicing and maintenance to ensure that your equip- ment is treated and stored properly.
Page 152 Storage Bringing Out of Storage When launching your boat for the first time or when starting out a new season, always carry out the steps provided in the following checklist: Reinstall all engine drain plugs. Reconnect any hoses removed for storage. Check condition of hoses;...
Page 153: Calibration And Settings
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. Calibrate the joystick function as follows: 1.
Page 154: Technical Data
Technical Data Engines Disclaimer Volvo Penta of the Americas reserves the right to make changes in weight, construction, materials, or specifications without notice or obligation. 47701898 12-2010...
Page 155 FUEL SYSTEM Fuel injection Port injection Fuel pumps Electric Fuel filter Volvo Penta, water separating, spin-on filter Fuel type See Gasoline Requirements in this section ELECTRICAL SYSTEM Charging system 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size...
Page 156 FUEL SYSTEM Fuel injection Port injection Fuel pumps Electric Fuel filter Volvo Penta, water separating, spin-on filter Fuel type See Gasoline Requirements in this section ELECTRICAL SYSTEM Charging system 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size...
Page 157 FUEL SYSTEM Fuel injection Port injection Fuel pumps Electric Fuel filter Volvo Penta, water separating, spin-on filter Fuel type See Gasoline Requirements in this section ELECTRICAL SYSTEM Charging system 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size...
Page 158 FUEL SYSTEM Fuel injection Port injection Fuel pumps Electric Fuel filter Volvo Penta, water separating, spin-on filter Fuel type See Gasoline Requirements in this section ELECTRICAL SYSTEM Charging system 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size...
Page 159 The oils are available at Volvo Penta dealers. If the Volvo Penta oils are not available, use a high quality oil that meets API SM and/or ILSAC GF-4 specifications. Viscosity should be SAE 5W30 or higher (examples;...
Page 160 Maintain oil level between E (add) and D (full) on the dipstick. If oil is added, use an approved Volvo Penta oil for gasoline engines; if unavailable, use a high quality oil that meets the Engine Oil Specifications.
Page 161 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.
Page 162 Volvo Penta gasoline engines are equipped with a water separating fuel filter (see Engine Fuel Filter Replacement in the section entitled Maintenance). The use of an additional water separating fuel filter between the fuel tank and the engine is recommended.
Page 163 The EFI system is controlled by a microprocessor, and requires no periodic mainte- nance or adjustment. If operational problems occur, see your Volvo Penta dealer. Detonation (Spark Knock) Detonation, or spark knock, is continually monitored by the electronic fuel injection (EFI) system. The EFI’s...
Page 164 Technical Data Electrical System Battery Cables When replacing battery cables, always use multi- strand copper cables of the same gauge (or better) as those already installed in your boat by the boat builder. If you are unsure of the gauge to be used, consult your dealer.
Page 165 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. NOTICE! Whenever you are changing or topping up the oil, always check the oil level using the dipstick.
Page 166 The engine decal is located on the engine cover. 51805 The transom assembly & drive unit stickers should be located on the engine decal. Your Volvo Penta dealer will have attached these stickers at the time that the transom assembly and drive unit were mounted on your boat and attached to the engine.
Page 167 Technical Data The California emission sticker is located on the engine cover. 22773–a The emission control Information sticker is located on the flat outside face (port side of engine) of the alter- nator support bracket. 22776–a The tune-up and color code decal is located on the engine cover.
Page 168 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(s). 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 the event of the boat being stolen.
Page 169 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 47701898 12-2010...
Page 170 4.3 GXiE-Q NOTICE! This Declaration of Conformity does not apply to boats using through-hull exhaust systems. Engine Manufacturer: Volvo Penta of the Americas, 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment...
Page 171 5.0 GXiE-P NOTICE! This Declaration of Conformity does not apply to boats using through-hull exhaust systems. Engine Manufacturer: Volvo Penta of the Americas, 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment...
Page 172 5.7 GiE-300-P, 5.7 GXiE-P NOTICE! This Declaration of Conformity does not apply to boats using through-hull exhaust systems. Engine Manufacturer: Volvo Penta of the Americas, 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment...
Page 173: Operator's Manual Order
(7–8 digits). http://vppneuapps.volvo.com/manual/coupon/ If internet access isn't possible, please contact your Volvo Penta dealer. All order information is stored internally at AB Volvo Penta and will not be shared with third parties. 47701898 12-2010...
Page 175: Alphabetical Index
Alphabetical index Freshwater System..........140 7" Color Display............27 Friction Brake............55 Accidents.............. 132 Fuel economy............30 Active Corrosion Protection System......59 Fuel Storage............138 Adding Oil if Low............ 158 Fuel System........... 137, 159 Alarm Display (Optional).......... 17 Gauges..............15 Alarms..............
Page 176 Vessel..............31 Viewable Options in the Main Menu......36 Volvo Action Service (VAS)........12 Volvo Penta Dealer Network........13 Volvo Penta on the Internet........13 Warranty Information..........12 Washing the Engine..........133 Water in Bellows............. 114 Water in Oil and Oil Level........114...

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