Volvo Penta 5.7 GiI-E Operator's Manual
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Volvo Penta 5.7 GiI-E Operator's Manual

Volvo Penta 5.7 GiI-E Operator's Manual

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OPERATOR'S MANUAL
5.7 GiI-E, 5.7 GXiI-F
8.1 GiI-F, 8.1 GXiI-E

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Summary of Contents for Volvo Penta 5.7 GiI-E

  • Page 1 OPERATOR’S MANUAL 5.7 GiI-E, 5.7 GXiI-F 8.1 GiI-F, 8.1 GXiI-E...
  • Page 2 CALIFORNIA PROPOSITION 65 WARNING Engine exhaust, some of its constituents, and a broad range of engine parts are known to the State of California to cause cancer, birth defects, and other reproductive harm. Additionally, lubricants, fuels, and other fluids used in engines–including any waste created through the wearing of engine parts–contain or produce chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 3 Volvo Penta product. As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice, service requirements and replacement parts.

  • Page 4: Table Of Contents

    Consumer Affairs Department ......10 Cooling System: Inhibiting ......46 Volvo Penta Dealer Network ......11 Fuel System............ 47 Volvo Penta on the Internet ......11 Fuel: General ..........47 Warranty Information ........11 Fuel Cell ............48 Warranty Registration Form ......11 Fuel Injection ..........

  • Page 5: Safety Precautions

    Make a point of familiarizing yourself with other operation or information in this owner’s manual, risk factors, such as rotating parts and hot please contact your Volvo Penta dealer. He will be surfaces (exhaust manifold, starter, etc.). able to help you with an explanation or will demon- Approaching a running engine is dangerous.
  • Page 6 19. Never work on an engine that is suspended on a hoist. 20. Components in the electrical, ignition, and fuel sys- tems on Volvo Penta products are designed and con- structed to minimize the risk of fire and explosion. Using non-original Volvo Penta parts that do not meet the above standards can result in fire or ex- plosion on board.

  • Page 7: Introduction

    These conditions are referred to as ISO 8665. All Volvo Penta engines meet the ISO 8665 standard. This ISO standard outlines the following fixed values or common conditions for deter- mining the rating of the engine.

  • Page 8: Stationwagon" Effect

    If your boat Tell friends or relatives about your route (that is, does not have an emergency stop switch, contact your file a “float plan”). Volvo Penta dealer, who can assist you in selecting one.

  • Page 9: Safety Equipment

    Even if the should carry at all times. See your Volvo Penta risk of being thrown overboard is practically nonexistent dealer.) in your type of boat, the risk of the driver falling and •...

  • Page 10: Certified Engines

    Instruction Manual concerning operation, service, and maintenance must be followed. NOTE! 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 specifi- cation being in accordance with the certified variant.

  • Page 11: General Information

    Penta product. The owner’s portion of this form is your Owner’s Identification Card. This card provides proof of ownership and is required to validate warranty, should warranty service be necessary. Warranty coverage may be delayed until the warranty and registration form is on file at Volvo Penta.

  • Page 12: Volvo Action Service (Vas)

    Dealers, or call 1-800-522-1959. Maintenance Schedule . Parts and Accessories Genuine Volvo Penta parts are the result of many hours of strenuous testing and fulfill Volvo Penta’s strict quality and safety requirements. Your authorized dealer has a complete line of (or may order) genuine Volvo Penta parts, accessories, coolants, and lubricants.

  • Page 13: Volvo Penta Dealer Network

    For the name and location of your nearest Volvo Penta dealer, consult the 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. Warranty Information Volvo Penta’s warranty package can be found in the accompanying warranty booklet.

  • Page 14: Features

    Features 5.7 GiI-E(F) – with HSW630A Transmission 5.7 GXiI-F(F) – with HSW630A Transmission 3590874-F 1. Alternator 12. Heat Exchanger End Cap 2. Coolant Circulation Pump 13. Raw Water Pump 3. Dipstick (Engine) 14. Serpentine Belt 4. Water Coolant Fill (Optional) 15.
  • Page 15 Features 3, 11 6, 7 3590874-S 3, 11 3590874-S 3, 11...
  • Page 16 Features 5.7 GiI-E(F) – with HSW630D Transmission 5.7 GXiI-F(F) – with HSW630D Transmission 3, 11 3590875-F 1. Alternator 12. Heat Exchanger End Cap 2. Coolant Circulation Pump 13. Raw Water Pump 3. Dipstick (Engine) 14. Serpentine Belt 4. Water Coolant Fill (Optional) 15.
  • Page 17 Features 3, 11 6, 7 3590875-S 3, 11 3, 11 3590875-T 3, 11...
  • Page 18 Features 5.7 GiI-E(F) – with HSW630V Transmission 5.7 GXiI-F(F) – with HSW630V Transmission 3, 11 3590873-F 1. Alternator 12. Heat Exchanger End Cap 2. Coolant Circulation Pump 13. Raw Water Pump 3. Dipstick (Engine) 14. Serpentine Belt 4. Water Coolant Fill (Optional) 15.
  • Page 19 Features 3, 11 6, 7 3590873-S 3, 11 3590873-T 3, 11...
  • Page 20 Features 8.1GiI-E(F) – with HSW630A Transmission 8.1GXiI-D(F) – with HSW630A Transmission 3590879-F 1. Alternator 12b. Raw Water Out 2. Coolant Circulation Pump 13. Raw Water Pump 3. Dipstick (Engine) 14. Serpentine Belt 4. Water Coolant Fill (Optional) 15. Starter 5. Flame Arrestor 16.
  • Page 21 Features 6, 7 3, 11 3590879-S 3, 11 3590879-T 3, 11...
  • Page 22 Features 8.1GiI-E(F) – with HSW630D Transmission 8.1GXiI-D(F) – with HSW630D Transmission 3590880-F 1. Alternator 12b. Raw Water Out 2. Coolant Circulation Pump 13. Raw Water Pump 3. Dipstick (Engine) 14. Serpentine Belt 4. Water Coolant Fill (Optional) 15. Starter 5. Flame Arrestor 16.
  • Page 23 Features 6, 7 3, 11 3590880-S 3, 11 3590880-T 3, 11...
  • Page 24 Features 8.1GiI-E(F) – with HSW630V Transmission 8.1GXiI-D(F) – with HSW630V Transmission 3590883-F 1. Alternator 12b. Raw Water Out 2. Coolant Circulation Pump 13. Raw Water Pump 3. Dipstick (Engine) 14. Serpentine Belt 4. Water Coolant Fill (Optional) 15. Starter 5. Flame Arrestor 16.
  • Page 25 Features 6, 7 3, 11 3590883-S 3, 11 3590883-T 3, 11...
  • Page 26 Features 8.1GiI-E(F) – with HSW800A2 Transmission 8.1GXiI-D(F) – with HSW800A2 Transmission 3590881-F 1. Alternator 12a. Raw Water In 2. Coolant Circulation Pump 12b. Raw Water Out 3. Dipstick (Engine) 13. Raw Water Pump 4. Water Coolant Fill (Optional) 14. Serpentine Belt 5.
  • Page 27 Features 6, 7 3, 11 3590881-S 3, 11 3590881-T 3, 11...

  • Page 28: Transmissions

    Transmissions Hurth HSW630A, HSW630D, & Transmission HSW800A2 Identification Plate Applies to the following engines: 5.7GiI-E(F), 5.7GXiI-F(F), 8.1GiI-E(F), & 8.1 GXiI-D(F) Shift Lever Neutral Switch Dipstick/Oil Fill 630A-1 630A-2 Transmission Identification Plate Neutral Switch Hurth HSW630V Applies to the following engines: 5.7GiI-E(F), Shift 5.7GXiI-F(F), 8.1GiI-E(F), &...
  • Page 29 Transmissions Borg Warner BW72C Applies to the following engines: Shift 5.7GiI-E(F) & 5.7GXiI-F(F) Lever Breather Neutral Switch Shift Lever 72C2 Dipstick/Oil Fill Transmission Identification Plate 72C1...

  • Page 30: Instrumentation

    Instrumentation The instrument panel for the Volvo Penta engines is equipped with a tachometer, temperature gauge, oil pressure gauge, voltmeter, 2 fuses, instrument panel lighting switch, and an ignition switch. Instruments, fuses, and ignition switch can also be supplemented with extra Volvo Penta instruments such as: synchronization tachometers, fuel gauge, fresh water gauge, clock, speed log, or rudder indicator.

  • Page 31: Fuses, 8 Amp

    Instrumentation 6. Fuses, 8 Amp Fuses for the starter function and system voltage (varies, depending on product manufacturer). To change fuses: Push in on the fuse holder and turn counterclock- wise. Important! Always carry extra fuses on board. 21180 7. Ignition Switch The ignition switch has three positions (varies, depend- ing on product manufacturer): 0 = The key can be inserted or removed.

  • Page 32: Emergency Stop Switch

    Small runabouts • Boats with sensitive steering • Boats where the distance from the top of the gunwale down to the driver’s seat is less than 30 cm (1foot). Contact your Volvo Penta dealer for installation of an emergency stop switch.

  • Page 33: Controls

    The shift function and engine speed control are combined in one lever. The shift function can be simply disengaged so that only engine speed is affected. The Volvo Penta controls are available for top or side mounting. The control levers have an adjustable friction brake. A neutral position switch, available as an accessory, allows the engine to be started with the drive disengaged.

  • Page 34: Adjustment Of Friction Brake

    Controls Adjustment of Friction Brake The friction brake affects only engine speed adjustment. Adjust with the lever in the throttle half open position (forward/reverse). • Remove the cover over the control. For side mounted controls the lever must first be removed.

  • Page 35: Starting The Engine

    Starting the Engine Familiarize yourself with the operation of the remote control supplied with your boat, then proceed as follows. IMPORTANT! Before pumping the bilge: Frequently check bilge for leaking engine oil, transmission oil, or other fluids. Find the cause and correct it immediately. Regulations prohibit the pumping of oil into any navigable waters.

  • Page 36: Starting

    Starting the Engine Starting Caution! Do not start engine out of water unless water supply is connected to the water intake. Before starting the engine, ensure that the engine flush system cap is tightly secured. • Move the control lever to the neutral/idle position. •...

  • Page 37: Operation

    Operation Caution! All shifting between forward/reverse must be done at engine idle speed. Shifting at higher speeds may damage the transmission and will also be uncomfortable for those on board. If the boat has two or three engines, it is important that they are all running during maneuvers astern (rearward movement), other- wise water might get into the exhaust of the engine which is not running when the backwash catches up with the boat.

  • Page 38: Engine Protection Mode

    NOTE: Should the problem continue, contact your 21197 nearest Volvo Penta dealer and have the engine checked. Master/Slave Installation For twin unit installations both engine ECMs can be tied together electronically.

  • Page 39: How To Shift And Control Speed

    Operation How to Shift and Control Speed Twin Unit Maneuvering NOTE! If your boat is equipped with a non-Volvo Penta When leaving or approaching the dock, or for any close remote control system, ask your dealer how to properly maneuvering at slow speed, place the starboard engine operate it.

  • Page 40: Cruising Speed

    Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed 25% lower than maximum rpm at WOT. Depend- ing on hull type, choice of propeller, load and condi- tions, etc., the maximum engine speed at top speed can...

  • Page 41: After Use

    After use To counteract boiling and heat stress the engine should be run for a few minutes at idle (in neutral) before turning it off. This is especially important if the engine has been operated at high engine speeds (rpm). Stopping the Engine •...

  • Page 42: Salt Water Operation

    After Use Salt Water Operation Your Volvo Penta engine is built for operation in either fresh or salt water. When removing the boat from the water, position the boat until the cooling system has drained thoroughly. See Maintenance section for proper...

  • Page 43: Maintenance Schedule

    Read the chapter Maintenance carefully before starting work. If there is any item you are not sure of, please contact your Volvo Penta dealer for more information. IMPORTANT! These service operations ‡ must be carried out by an authorized Volvo Penta Service workshop. DAILY BEFORE STARTING FIRST TIME Engine: Check oil level ..........................

  • Page 44: Maintenance And Care

    Maintenance and Care Volvo Penta engines and transmissions are designed for maximum service life and reliability. They are built to survive in a tough marine environment, but also to cause as little environmental impact as possible. In order for your engine and transmission to operate reliably, regular maintenance is necessary.

  • Page 45: Oil Level: Checking And Topping-Up

    The oil is cooled in the oil cooler (not all models) and cleaned in the oil filter. Always use Volvo Penta original oil filters as they have an integral relief valve allowing the oil to bypass the filter even if the filter is completely clogged.

  • Page 46: Cooling System

    If overheating still occurs, return to port at low RPM to prevent excessive overheating and engine damage. See your Volvo Penta dealer for service assistance. If there is a risk of the air temperature reaching frost levels, the cooling system must be drained.

  • Page 47: Draining The Cooling System

    Maintenance and Care Draining The Cooling System (Optional Closed Cooling System) Using a 9/16 inch wrench, loosing the lower heat exchanger cover bolt (A) approximately three turns but do not remove. With the cover bolt loose, turn the cover plate in either direction to allow the water to drain from the heat exchanger.

  • Page 48: Cooling System: Inhibiting

    Maintenance and Care Cooling System: Inhibiting When laying up the boat for the winter it is important that the cooling system be flushed with fresh water so that deposits do not dry and to prevent the buildup of salt crystals. Seawater in the system causes corrosion when air is introduced and can cause the buildup of salt crystals that could block the system.

  • Page 49: Fuel System

    This knocking sound while annoying also cases real damage to the engine and decreases engine life and performance. The fuel injection system on Volvo Penta engines have a device know as a knock sensor which detects engine knock and prevents engine damage. However, the use of low octane fuel will give poor performance.

  • Page 50: Fuel Cell

    DANGER! Frequently check the fuel cell for signs of fuel leakage. Should signs of leakage develop, have it serviced immediately by your Volvo Penta dealer. The fuel cell has two electric fuel pumps, a filter and a vapor separator/fuel cooler tank. The low pressure fuel pump (2) draws fuel from the fuel tank through the fuel filter (1).

  • Page 51: Fuel Filter: Replacement

    NOTE! A loud whining noise at idle may occur due to a restricted fuel filter causing a noisy fuel pump. Operating the engine with a restricted filter may damage the pressure regulator or fuel pumps. See your Volvo Penta dealer if pumps make abnormal noise. Preventing Gum Formation and...

  • Page 52: Electronic Engine Control

    It has a memory that stores diagnostic information in the form of service codes to aid your Volvo Penta dealer when diagnosing performance problems. Contact your Volvo Penta dealer if service is required.

  • Page 53: Electrical Systems

    Maintenance and Care Electrical Systems The electrical system is 12 volts. The alternator produces 14 volts when the engine is running and has an integrated voltage regulator. The engine also has circuit breakers and fuses, in a fuse box, which cut off the current if there is an overload.

  • Page 54: Electrolytic Corrosion

    When you need to purchase new anodes, see your Caution! Volvo Penta dealer. The material composition of Volvo Penta anodes meets U.S. Military Specification 18001- Electrolytic corrosion as a consequence of H. Some after-market anodes may not meet mil-specs leakage currents may cause serious damage to and are larger in size.

  • Page 55: Main On/Off Power Switch

    For the same reason charging circuits must never be switched over while the engine is running. To simulta- neously charge two independent battery circuits, fit a Volvo Penta charge distributor (accessory) to the regular generator. Caution! Turn the engine off and switch off power at the main switches before carrying out work on the electrical system.

  • Page 56: Cleaning

    Maintenance and Care Cleaning Keep batteries dry and clean. Oxidation or dirt on the battery and battery terminals can cause short-circuits, voltage drop and discharge, especially in damp weather. Clean the battery terminals and leads to remove oxidation using a brass brush. Tighten the cable terminals well and grease them with terminal grease or petroleum jelly.

  • Page 57: Engine Alignment

    This should be done when the drive unit is removed for lubrication during off-season storage preparations. Because of the special tools required, engine alignment must be performed by a Volvo Penta dealer. Caution! Failure to check engine alignment could result...

  • Page 58: Laying-Up & Launching

    Laying-up & Launching Before taking the boat out of the water for the winter or for out-of-season storage have an authorized Volvo Penta workshop inspect the engine and other equipment. Have any necessary repairs or service work carried out so that your boat is in top condition and ready for the next season.

  • Page 59: Launching

    Laying-up & Launching Launching Check oil level in the engine and transmission. Top Check the condition of rubber hoses and check off if required. See Technical Data for oil quality. hoses to ensure they are securely clamped in NOTE! If there is inhibiting oil in the system, drain, place.

  • Page 60: Painting The Drive And Underwater Hull

    In some cases these agents are completely forbidden for use on leisure craft. In these cases ask your Volvo Penta dealer for advice about alternative methods. IMPORTANT! Find out what regulations apply to the use of antifouling agents.

  • Page 61: Troubleshooting

    Troubleshooting A number of symptoms and possible reasons for engine problems are described in the table below. In case of faults or mishaps which you cannot solve, always contact the Volvo Penta dealership. WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.

  • Page 62: Technical Data

    Volume between MAX and MIN on the dipstick (liters) .......... 1 quart (0.95 liters) Oil grade in accordance with the API system ............Synthetic Service CF/SH Viscosity at 0°C (32°F)+ ..................Volvo Penta Synthetic Motor Oil. Viscosity at -5°- +50°C (23°-122°F) ............... 15W40 Mineral Oil 15W50 Synthetic Oil Oil Filter Volvo Penta part no ..................
  • Page 63 Volume between MAX and MIN on the dipstick (liters) ......... 1 quart (0.95 liters) Oil grade in accordance with the API system ..........Synthetic Service SH Viscosity at 0°C (32°F)+ ................Volvo Penta Synthetic Motor Oil. Viscosity at -5°- +50°C (23°-122°F) .............. 15W40 Mineral Oil ........................

  • Page 64: Fuel Specification

    Technical Data Fuel Specification. See chapter Fuel System for more information. Inside US ........................ 87 Octane (R+M)/2 Outside US ......................90 Octane (RON)* *SAV & CARB Certification will be void if leaded gasoline is used. WARNING! Fuel is extremely flammable and highly explosive under certain conditions. Always stop the engine and do not smoke or allow open flames or sparks near the boat when refuelling.

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5.7 gxii-f8.1 gii-f8.1 gxii-e

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