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Summary of Contents for Volvo Penta 4.3OSi-E
- Page 1 OPERATOR’S MANUAL 4.3OSi-E, 4.3OSi-EF 5.0OSi-E, 5.0OSi-EF 5.7OSi-D, 5.7OSi-DF 5.7OSXi-D, 5.7OSXi-DF...
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Page 3: Table Of Contents
Top mount control ..... . 34 4.3OSi-E ......18 Steering system operation . - Page 4 Contents Engine exhaust system ....43 Warranty information ....67 Drive unit bellows .
- Page 5 DANGER! Failure to comply with a danger symbol contact your Volvo Penta dealer. He will be able to help will result in serious injury or death to boat operator, you with an explanation or will demonstrate the operation.
- Page 6 Introduction Below is a summary of the risks and safety precautions 14. Never allow an open flame or electric sparks near the you should always observe or carry out when operating or battery or batteries. Never smoke in proximity to the bat- servicing the engine: teries.
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Page 7: Introduction
From engineering design and you use it. Contact an authorized Volvo Penta dealer if you manufacturing to support activities in Parts, Service, and cannot correct the fault yourself. -
Page 8: Factors That Affect Engine Performance
These conditions are referred to more in order to counter the effects of the increase in as ISO 8665. All Volvo Penta engines meet the ISO 8665 overall weight encountered in normal cruising, particularly standard. This ISO standard outlines the following fixed in hotter climates. -
Page 9: Your New Boat
If your boat near the boat. does not have with an emergency stop switch, contact your Volvo Penta dealer, who can assist you in selecting • Avoid standing up or shifting weight suddenly in small, one. -
Page 10: High Performance Boat Operation
Introduction High performance boat operation High performance is not only defined by engine size, but by a combination of engine power (horsepower), hull design, and the size of the boat. Your new engine(s) produce a high power output. Depending on the boat type, the top speed may be much higher than what you are accustomed to. -
Page 11: Product And Application Information
Check page 11 for the location of product serial number plates. © 2002, Volvo Penta of the Americas, Inc. Volvo, Volvo Penta, DP Duoprop, and (Aquamatic) are ® of AB Volvo. DPX and QL are ® of AB Volvo Penta. DuraPlus, 2PLUS4, Speed Rails, and Xact are trademarks of Volvo Penta of the Americas, Inc. -
Page 12: General Information
All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. Volvo Penta of the Ameri- cas, Inc. reserves the right to make changes at any time, without notice, in specifications and models; to discontinue models;... -
Page 13: Volvo Action Service (Vas)
Membership to Volvo Action Service is provided automati- cally to all Volvo Penta engine owners. As long as your Volvo Penta engine is under factory warranty, this service is absolutely free for Volvo Penta-related repairs. Towing is not covered by the Volvo Penta warranty. -
Page 14: Volvo Penta Dealer Network
Yellow Pages under Boat Dealers, or call 1-800-522-1959. Volvo Penta on the Internet The URL address for Volvo Penta of the Americas is http:/ /www.volvopenta.com. When you reach the Volvo home page, choose the Marine and Industrial Engines icon. -
Page 15: Features
Your Volvo Penta product consists of two components: the engine and the drive. There are certain parts on each compo- nent that you, the owner, must take care of to make sure that your Volvo Penta product stays in optimum running condi- tion. -
Page 16: 4.3Osi-Ef
Features 4.3OSi-EF Top View 1. Flame Arrestor (under cover) 9. Raw Water Pump & Impeller 18. Engine Drain 2. Alternator 10. Fuel Pumps 19. Drain (manifold) 3. Engine Oil Filter 11. Fuel Filter 20. Anodes (hidden) 4. Oil Dipstick (engine) 12. - Page 17 Features 4.3OSi-EF Starboard View 4.3OSi-EF Port View 7742836 07-2003...
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Page 18: 5.0Osi-Ef, 5.7Osi-Df, 5.7Osxi-Df
Features 5.0OSi-EF, 5.7OSi-DF, 5.7OSXi-DF Top View 1. Flame Arrestor (under cover) 9. Raw Water Pump & Impeller 18. Engine Drain 2. Alternator 10. Fuel Pumps 19. Drain (manifold) 3. Engine Oil Filter 11. Fuel Filter 20. Anodes (hidden) 4. Oil Dipstick (engine) 12. - Page 19 Features 5.0OSi-EF, 5.7OSi-DF, 5.7OSXi-DF Starboard View 5.0OSi-EF, 5.7OSi-DF, 5.7OSXi-DF Port View 7742836 07-2003...
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Page 20: 4.3Osi-E
Features 4.3OSi-E Top View 1. Flame Arrestor (under cover) 13. Engine Flush 2. Alternator 14. Exhaust Clamps 3. Engine Oil Filter 15. Circuit Breaker/Fuses (under cover) 4. Oil Dipstick (engine) 16. Exhaust Riser 5. Oil Withdrawal Tube 17. Exhaust Manifold 6. - Page 21 Features 4.3OSi-E Starboard View 4.3OSi-E Port View 7742836 07-2003...
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Page 22: 5.0Osi-E, 5.7Osi-D, 5.7Osxi-D
Features 5.0OSi-E, 5.7OSi-D, 5.7OSXi-D Top View 1. Flame Arrestor (under cover) 13. Engine Flush 2. Alternator 14. Exhaust Clamps 3. Engine Oil Filter 15. Circuit Breaker/Fuses (under cover) 4. Oil Dipstick (engine) 16. Exhaust Riser 5. Oil Withdrawal Tube 17. Exhaust Manifold 6. - Page 23 Features 5.0OSi-E, 5.7OSi-D, 5.7OSXi-D Starboard View 5.0OSi-E, 5.7OSi-D, 5.7OSXi-D Port View 7742836 07-2003...
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Page 24: Anodes ("Sacrificial")
2. Belts (may also be involved with other engine systems) Use only genuine Volvo Penta anodes. Some aftermar- 3. Hoses and clamps ket anodes may not meet mil-specs and are larger in size. -
Page 25: Electronic Fuel Injection (Efi)
Do not attach the lanyard to clothing that will Before operating your Volvo Penta product, familiarize yourself with the instruments supplied with your boat. (Some boats may not have Volvo Penta instruments. Read the boat’s owner’s manual to become familiar with the instruments used.) tear away before the lanyard is pulled from switch to stop the engine. -
Page 26: Engine Instruments
Operation Engine instruments (1) Tachometer: Indicates engine revolutions per minute (RPM). (2) Speedometer: Indicates boat speed in miles per hour X 100 (MPH). r / min 22076 22382 (3) Voltmeter: With ignition on, engine not running, indicates battery voltage. With engine running, indicates alternator voltage output. -
Page 27: Trim/Tilt Motor Protection
Operation Caution! Operating in beach range or lift range will cause signifi- cant loss of maneuverability. Operating in beach range above idle speed, or for prolonged periods of time, may cause serious drive damage. LED display: Certain LEDs display at certain times for the digital trim instrument: Flashes red within the range above 41. -
Page 28: If You Strike A Solid Object
Check the engine compartment for water leakage. If there is obvious or suspected damage, operate the boat at low RPM and take it to a Volvo Penta dealer for inspec- tion. Have necessary repairs made immediately. Only operate your boat if absolutely necessary. Operating a damaged unit could cause additional damage and could become very costly to repair. -
Page 29: Propellers
Volvo Penta makes a complete line of propellers designed to match the performance of the SX, DP, DPX, and XDP sterndrives. For every combination of engine, sterndrive, hull, and application there is a Volvo Penta propeller that provides optimum performance. Many factors influence the way a propeller performs, including hull shape, onboard weight, engine horsepower, power trim, and the way the boat is used. -
Page 30: Twin Engine Installation
To provide your boat with the best engine life, fuel economy, and performance, select the correct propeller to allow the engine to run at full throttle in the recommended operating range. Your Volvo Penta dealer will help you to choose the correct propeller(s) for your application. Caution! Replace a damaged propeller right away. -
Page 31: Remote Controls
Use only a remote control unit with start-in-neutral-only feature. This feature can prevent injury resulting from the propeller turning unexpectedly, or the boat moving suddenly. The shift mechanism on all Volvo Penta controls can be disengaged to allow for easier starting and engine warm-up. Trim controls... -
Page 32: Control Lever
Operation Control lever The control button on the control lever (3) has two func- tions: • Pressing the top half of the button moves the drive trim out while it the raises the boat’s bow • Pressing the bottom half of the button moves the drive trim in while it the lowers the boat’s bow. -
Page 33: Engine Break-In Period
Below 0°F (-18°C) ..........SAE10W NOTE! To ensure proper lubrication during the break-in *Recommended - SAE 30 Volvo Penta DuraPlus Synthetic Motor Oil (P/N 3851230-7 period, do not remove factory break-in oil until after U.S. and Canada only). If the Recommended oil is not available, use pure synthetic the 20-hour break-in is completed. -
Page 34: First Two Hours
No leakage of fuel, oil, water, or exhaust gases occurs. • Engine oil pressure and temperature are normal. This is a perfect time to discuss with your Volvo Penta dealer any questions about your engine that may have arisen during the first 20 hours of operation and establish a routine preventive maintenance schedule. -
Page 35: Operating After Break-In Period
Operation Operating after break-in period If the engine floods: Advance the control handle to full throttle to clear a After the break-in period, the engine can be operated at flooded engine. In this throttle position, with the engine any RPM from idle to full throttle. Cruising at 3600 RPM or speed below 400 RPM (cranking speed), the ECM turns off less, saves fuel, reduces noise, and prolongs engine life. -
Page 36: Stopping The Engine
Stopping the engine Steering system operation 1. Move the remote control handle to NEUTRAL. The steering system for your Volvo Penta sterndrive is operated by a steering cable connected to the helm. 2. Turn ignition key to OFF. Restricting movement of the steering cable will limit or stop the steering system’s hydraulic assist. -
Page 37: Power Trim And Tilt Operation
Operating in “bow-up” position water conditions. If you experience boat instability and/ or high steering torque, see your Volvo Penta dealer to The “bow-up” position is normally used for cruising, correct these conditions. -
Page 38: Power Tilt Operation
Any malfunction of the trim/tilt system could result in a loss of impact protection. Malfunction can also result in loss of reverse thrust capability. If malfunction occurs, see your authorized Volvo Penta dealer. Power trim/tilt switch operation Trimming and tilting the drive is done from a control switch mounted on the remote control or by using the switches on the dash. -
Page 39: Power Trim/Tilt Switch And Gauge Location
Operation Power trim/tilt switch and gauge location The power trim/tilt switch is located on the remote control handle or on the boat’s dashboard. The trim indicator displays the drive position in the Trim range. With dual installations, it is permissible to individually trim the drive in Trim range. -
Page 40: Checking Instruments
Operation If you suspect there is a problem, see your Volvo Penta dealer as soon as possible for proper diagnosis and re- quired service or adjustment. Continued operation could result in damage to the shift mechanism and loss of shift and throttle control that could result in personal injury. -
Page 41: Special Boating Circumstances
Operation Special boating circumstances Salt water operation Your can use your Volvo Penta sterndrive in either fresh or Engine protection mode operation salt water. In a low oil pressure or engine overheat situation, the EFI system enters an Engine Protection Mode. When this... -
Page 42: Trailering Your Boat
43 MPH (35 knots). F-series stainless steel propeller sets should be used in these applications. If you use D-series aluminum propeller sets, you must also use an in-trim limiter kit. See your Volvo Penta dealer. 100% Full throttle Full Throttle... -
Page 43: Maintenance Schedule
Maintenance Maintenance schedule The operation, maintenance, and care of the Volvo Penta engine and power package as outlined in the owner’s manual are the owner’s responsibility. The owner must keep records of all maintenance services performed. This record of proper maintenance may be required to determine warranty coverage on certain repairs and should be transferred to each subsequent owner. - Page 44 Maintenance Function Adjust Check Lubricate Fill Replace Tighten Once per season Drive unit bellows and clamps** • • Exhaust manifold and risers • Distributor cap and rotor • Fuel filter • Fuel system leaks • Raw water pump impeller • Engine oil †...
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Page 45: Preparing For Boating After Storage (Launching)
Off-season storage (“winterization”) Be sure to properly winterize your Volvo Penta equipment. Engine or drive damage can result from ignoring simple preventive maintenance steps during autumn. Winterizing gives you the assurance that your engine will run more reliably and economically in the springtime. -
Page 46: Fuel System
Failure to inspect your work could allow fuel leakage to performance. Volvo Penta suggests the use of 89 AKI or go undetected. This could become a fire or explosion higher fuels. -
Page 47: Flame Arrestor
IF YOU CAN SMELL FUEL, TURN THE ENGINE OFF IM- MEDIATELY — EXPLOSION AND FIRE ARE AN EXTREME running. If a pump does not function, check the fuses and replace them if necessary. See your Volvo Penta dealer if DANGER. further service is required. -
Page 48: Electrical System
Spray battery terminals and connections with and anti- begin installation. corrosive agent, or coat them with petroleum jelly. 1. The correct battery for all Volvo Penta EFI engines is a standard marine battery with a minimum of 650 CCA and •... - Page 49 Operate the boat’s bilge blower for at least 5 minutes. Open the engine cover or hatch and check the See your Volvo Penta dealer for recommendations on boat’s bilge area for gasoline fumes. If any fumes can installing multiple batteries.
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Page 50: Spark Plugs
Remove, inspect and clean the distributor cap and rotor. Replace these components if worn or damaged with genuine Volvo Penta parts. No other distributor parts require service or replacement. Be sure spark plug leads are replaced in the correct firing order (see the table below). -
Page 51: Checking And Changing Spark Plugs
Maintenance Checking and changing spark plugs 1. Twist and pull only on the spark plug wire boot (pulling on wire may cause separation of the core of the wire). 2. Remove spark plugs using a 5/8-inch spark plug socket or a 5/8-inch box wrench. Use care to avoid cracking the spark plug insulators. - Page 52 Maintenance 7. Examine interior of plug in good light. Remove any clean- ing compound with compressed air. If traces of carbon or oxide remain in plug, finish the cleaning with a light blast- ing operation. Clean firing surfaces of center and side electrodes with several strokes of a fine cut file.
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Page 53: Belt Adjustments
Maintenance Belt Adjustments WARNING! To prevent possible injury caused by someone inadvert- Alt. ently starting the engine, remove the ignition keys from each starting location (especially if the engine room/en- gine compartment cannot be seen from various remote starting positions such as a flybridge or enclosed cabin). The Ocean Series engines use a serpentine belt, which is Circ. -
Page 54: Cooling System
6. If overheating still occurs, return to shore at low RPM (to prevent excessive overheating and engine damage). 7. See your Volvo Penta dealer for service assistance. If the engine overheats at high engine speeds, the engine protection mode feature will activate and an alarm may sound: •... -
Page 55: Draining The Cooling System
Volvo Penta dealer for a complete end-of-season/ winterization service. Freeze damage to the engine package is not covered by your Volvo Penta limited warranty. • Perform these procedures with the boat out of the wa- ter. -
Page 56: Raw Water Cooled
Maintenance Raw Water Cooled 1. With the engine off locate and open the engine drain petcocks located on the side of the engine block. See Features page for petcock and drain locations. If water does not drain from the petcock, use a small piece of wire to open the drain hole. -
Page 57: Closed Cooling System
(check antifreeze manufacturer’s instructions). Make sure the freeze point is adequate for expected temperatures. To drain the raw water system of your engine with factory installed closed cooling on your Volvo Penta engine. Note! The boat should be out of the water and the bow down slightly to allow complete drainage. -
Page 58: Power Trim/Tilt Fluid Level
This procedure requires the removal of the drive unit; therefore, your Volvo Penta dealer should do it. An ideal time to have this done is during the winterization process. Failure to have primary shaft splines lubricated each year may result in damage to the drive unit. -
Page 59: Engine/Crankcase Oil
At the end of the break-in period (20 hours), change the crankcase oil and replace the oil filter. Refer to the Mainte- *Recommended - SAE 30 Volvo Penta DuraPlus Synthetic Motor Oil (P/N 3851230-7 U.S. and Canada only). If the Recommended oil is not available, use pure synthetic nance Schedule for recommended oil change intervals. -
Page 60: Changing Engine Oil
The gimbal bearing and universal joints are permanently lubricated. No external lubrication is required. Lubricating the drive unit (XDP) The drive unit is filled at the factory with Volvo Penta DuraPlus GL5 Synthetic gearcase lubricant. This lubricant must be used when adding lubricant or refilling the drive unit. -
Page 61: Anodes ("Sacrificial" Anodes)
When you need to purchase new anodes, see your Volvo Penta dealer. The material composition of Volvo Penta anodes meet stringent standards. If you use other anodes, make sure they have equivalent specifications or galvanic corrosion protection will be lost. -
Page 62: Neutra-Salt System
Maintenance Neutra-Salt System NOTE! Check all local and regional regulations when dis- charging any chemical into the water. Some areas may prohibit the discharge of Neutra-Salt into the water. The Neutra-Salt system is only intended for use in engines that operate in salt or brackish water. It is not intended for engines used in fresh water. - Page 63 Maintenance 2. The engine must be running for the sea water pump to pull the concentrate from the reservoir. If the boat is not in the water make sure there is a good supply of water for the engine. Start the engine and run at idle. Caution! X 100 Ensure the engine has an adequate water supply.
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Page 64: Propeller Care
If the rubber hub should begin to slip, it can be easily replaced at an authorized Volvo Penta dealer or propeller repair station. Caution! Protect your hands from the sharp edges of the propel- ler blades. -
Page 65: Propeller Installation
22397 the Power and Propeller Performance Charts . Tools for removing and installing the propellers are contained in Volvo Penta’s propeller tool kit, P/N 3862811. Caution! D-series aluminum propeller sets used on Duoprop ap- plications are not recommended for use on boat and engine combinations capable of speeds in excess of 40 MPH. -
Page 66: X-Series
Power and Propeller Performance Charts . Tools for removing and installing the propellers are contained in Volvo Penta’s propeller tool kit, P/N 3862811. Caution! 22393 X-series composite propeller sets used on Ocean Se- ries applications are not recommended for use on the 5.7OSi and 5.7OSXi engine combinations. -
Page 67: Replacement Parts
Bottom painting may also be desirable. rine applications. Bottom painting Failure to use genuine Volvo Penta parts may result in If your boat is in water where marine growth is a problem, product malfunction and possible injury to the operator using an anti-fouling paint may reduce the growth rate. -
Page 68: Troubleshooting
Emergency stop switch Reinstall lanyard (if installed) Fuel system problems See your Volvo Penta dealer Replace filters. See your Volvo Fuel filters Engine runs eratically Penta servicing dealer See your Volvo Penta servicing... -
Page 69: Problem Resolution
Volvo Penta owner and a dealer. If this happens to you, Volvo Penta importers and dealers in those areas. Contact your local and your dealer will work together to pursue a reasonable Volvo Penta representative for a copy. -
Page 70: Certified Engines
Always contact your cation decals placed on the engine, one on the starboard Volvo Penta dealer if you are unsure of anything to do with high-rise bracket and the other on the front of the port your engine’s function or maintenance. -
Page 71: Specifications
Spark plug gap ..........0.060 inches (1.52 mm) Spark plug installation torque ......20 ft. lb. (27 Nm) NOTE! Volvo Penta of the Americas, Inc., reserves the right specifications without notice or obligation. to make changes in weight, construction, materials, or... -
Page 72: Osi
Outside the U.S.: 90 octane (RON) unleaded gasoline Full throttle operating range ......4600 – 5000 RPM Idle RPM (fixed) ..........600 RPM Ignition timing ........... Authorized Volvo Penta dealer service only Oil Capacity Engine .............. Without filter: 5 quarts (4.7 liters) With filter: 6 quarts (5.7 liters) -
Page 73: 5.7 Osi/Osxi
OSXi: 4600 – 5000 RPM Idle RPM (fixed ..........OSi: 600 RPM OSXi: 600 RPM Ignition timing ........... Authorized Volvo Penta dealer service only Oil Capacity Engine .............. Without filter: 5 quarts (4.7 liters) With filter: 6 quarts (5.7 liters) Drive unit ............ - Page 74 Notes ...................
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