Volvo Penta 4.3GL Instruction Book
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Volvo Penta 4.3GL Instruction Book

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INSTRUCTION BOOK
3.0GS, 4.3GL/GS/Gi
5.0GL/Gi, 5.7GS/GSi

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  • Page 1 INSTRUCTION BOOK 3.0GS, 4.3GL/GS/Gi 5.0GL/Gi, 5.7GS/GSi...
  • Page 3 Welcome aboard Congratulations on your new boat and your choice of a Volvo Penta marine engine. A choice that will give you many years of boating pleasure. Your new marine engine is the result of 90 years experience in marine engine...

  • Page 4: Table Of Contents

    How to shift and control speed ......30 Twin unit maneuvering .......... 30 Cruising speed ............31 Power Trim ............31 © 1998 AB VOLVO PENTA All rights to changes or modifications reserved. Printed on enviornmentally friendly paper. (Cover: Department of transport (shipping), license 9809095)

  • Page 5: Safety Precautions

    Read the Instruction Manual carefully before operating or servicing the engine. If anything is unclear please contact your Volvo Penta dealer for assistance. This symbol is used in the book and on the engine to make you aware of safety information.

  • Page 6: Safety Precautions To Be Taken When Operating The Boat

    Safety precautions to be taken when operating the boat to happen. Your new boat Read Instruction Manuals and other information Maneuvering supplied with your new boat. Learn to operate the Avoid violent and unexpected changes in course and engine, controls and other equipment safely and cor- gear engagement.
  • Page 7 rate the problem are wind conditions, load distribu- Carbon monoxide poisoning tion, sea conditions, trim, open hatches and ventil- When a boat moves forward through the water a va- ators etc. cuum is created behind it to a greater or lesser ex- Most modern boats are designed so that vacuum ef- tent.

  • Page 8: Safety Precautions For Maintenance And Service

    Never undertake an operation if you are not com- Store oil and fuel soaked rags and other flammable pletely sure how to do it. Contact your Volvo Penta material in fireproof conditions. In certain circumstan- dealer for assistance instead.
  • Page 9 Hot surfaces and liquids Lubrication system When the engine is at operating temperature there is Hot oil can cause burns. Avoid skin contact with hot always a danger of burns. Avoid hot surfaces. For oil. Ensure that the lubrication system is not under example: exhaust manifold, oil sump, hot coolant and pressure before commencing work on it.

  • Page 10: Introduction

    Introduction This Instruction Manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the Instruction Manual carefully and learn how to operate the engine, controls and other equipment safely.

  • Page 11: Certificated Engines

    Warranty and Service book. Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service and maintenance which you, the owner, must be aware of, check and carry out.

  • Page 12: Identification Numbers

    Identification numbers Your engine and transmission has identification plates with identification numbers. This information should al- ways be quoted when ordering service and replacement parts. There are probably similar plates on your boat and its equipment. Make a note of the details below, make a copy of the page and keep it so that you have a copy should the boat be stolen.
  • Page 13 Type Approval Number A type approval number is assigned to an engine model when it is certified for exhaust emissions. There are two certification decals placed on the engine to verify engine certification; one on the EFI computer cover, and the other at the front of the port cylinder head (A).

  • Page 14: Orientation

    Orientation Please note! The photos below do not show all engine/transmission combinations. If your engine does not have the drive shown, refer to another engine with the relevant drive for an introduction to the transmission. Engine 3.0GS Starter Motor Oil Withdrawal Tube Oil Filter Fuel Pump Oil Level Dipstick...
  • Page 15 Engine 4.3GL, 4.3GS, 4.3Gi Starter Motor Oil Withdrawal Tube Oil Filter Fuel Pump Oil Level Dipstick Circuit Breakers Type Plate (engine) Water-Cooled Exhaust Pipe Type Plate (shield) 10. Seawater Pump SX Drive 16. Draining Oil 17. Seawater Intake 18. Sacrificial Anodes 19.
  • Page 16 Engine 5.0GL, 5.0Gi, 5.7GS, 5.7GSi Starter Motor Oil Withdrawal Tube Oil Filter Fuel Pump Oil Level Dipstick Circuit Breakers Type Plate (engine) Water-Cooled Exhaust Pipe Type Plate (shield) 10. Seawater Pump DP-S Drive 16. Draining Oil 17. Seawater Intake 18. Sacrificial Anodes 19.

  • Page 17: Instrumentation

    Instrumentation The instrument panel for Volvo Penta petrol engines is equipped with a tachometer, temperature gauge, oil pressure gauge, voltmeter, 2 fuses, instrument lighting switch and an ignition switch. Instruments, fuses and ignition switch can also be installed separately without an instrument panel. The boat builder’s instrumentation 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 18 6. Fuses, 8 A Fuses for the starter function and system voltage. To change fuses: Press the button and turn anti- clockwise. IMPORTANT Always carry extra fuses on board. 7. Ignition switch The ignition switch has three positions (these positions are not marked): 0 = The key can be inserted and taken out.

  • Page 19: Emergency Stop Switch

    High performance sport boats 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. See your Volvo Penta dealer for installation of an emergency stop switch.

  • Page 20: 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 is available as an accessory, this will only permit the engine to be started with the drive disengaged.
  • Page 21 Adjustment of friction brake The friction brake only affects engine speed adjust- ment. 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. Adjust the friction brake by turning the screw at the arrow (see figure).

  • Page 22: Power Trim

    Power Trim Your Volvo Penta drive has a Power Trim system as standard equipment. The purpose of Power Trim is to al- low the helmsman to change the angle at which the drive is set, without leaving the cockpit. Changing this angle relative to the bottom of the boat is referred to as trimming.
  • Page 23 Control lever Control button (2) in the control lever is used to raise the bow, by pressing the top half, and to lower the bow by pressing the lower half of the button. To put the drive in the “Beach” position, you have to press a se- parate switch to bypass the catch which prevents entry to the “Beach”...

  • Page 24: Trim Instruments

    Trim instruments The SX drive only has an analogue trim instrument. The DP-S drive can either have an analogue or digital trim in- strument. Analogue trim instrument (SX, DP-S) The trim instrument indicates the current trim position. It has a scale with five segments and three main ranges: 1.
  • Page 25 TRIM = Drive position at all speeds. Max trim up to 5. BEACH = Used for operation at in shallow water where water depth is uncertain. Speed should always be low, max. 1000 rpm. 5 - 40. LIFT = Flashing red warning lamp. Drive up completely 41 - 51. See LEDs position 1.

  • Page 26: Impact Protection

    If there is obvious or suspected damage, operate boat at low RPM and take your boat to a Volvo Penta dealer for inspection. Have necessary repairs made immediately. Operating a damaged drive unit could cause additional damage and could become very costly to repair.

  • Page 27: Starting The Engine

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

  • Page 28: Starting

    Starting NOTE! Do not start engine out of water unless using a flushing adapter. WARNING! When using a flushing adaptor, remove the propellers befor starting engine to prevent accidental con- tact with moving propellers. If propellers are not removed, personal injury could result. Move the control lever to the neutral/idle position.

  • Page 29: If Engine Floods

    If engine floods Gi, GSi models: A flooded engine can be cleared by advancing the control handle to a position of 3/4 throttle. In this throttle position and the engine speed below 400 RPM (cranking speed) the ECM turns off the fuel injectors so no fuel is delivered. When the th- rottle position is moved to full throttle or less than 3/4 throttle, the ECM returns to the starting mode.

  • Page 30: Operation

    Operation All shifting between forward/reverse must be done at engine idle speed. Shifting at higher speeds may damage the drive/reverse gear 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), otherwise water might get into the exhaust of the engine which is not running when the backwash catches up with the boat.

  • Page 31: Engine Protection Mode

    NOTE: Should the problem continue, contact your nearest Volvo Penta dealer and have the engine checked. Master/slave installation Gi, GSi For twin unit installations both engine EMCs can be tied to- gether electronically.

  • Page 32: How To Shift And Control Speed

    How to shift and control speed Twin unit maneuvering NOTE! If your boat is equipped with a non-Volvo When leaving or approaching the dock, or for any Penta remote control system, ask your dealer how to close maneuvering at slow speed, place the star- properly operate it.

  • Page 33: Cruising Speed

    WOT range. Wide Open Throttle (WOT) range: 3.0GS .......... 4200–4600 rpm 4.3GL .......... 4200–4600 rpm 4.3GS/Gi ........4400–4800 rpm 5.0GL .......... 4400–4800 rpm 5.0Gi ..........4800–5000 rpm 5.7GS ..........
  • Page 34 When starting Trim the drive. The bow will be pressed down and the boat ac- celerates faster. This gives improved running and steering characteristics at speeds below the planing threshold. At planing speed Trim the drive out to the running position which feels comforta- ble and the boat feels stable and smooth.
  • Page 35 If a propeller has been damaged it must be replaced. Launch the boat and test drive. If there are still vibrations it must be inspec- ted by an authorized Volvo Penta workshop. IMPORTANT To prevent galvanic corrosion any damage to...

  • Page 36: After Use

    After use To counteract boiling and heat stress the engine should be run for a few minutes at idle (in neutral) before tur- ning it off. This is especially important if the engine has been operated at high engine speeds (rpm). Before stopping the engine: The drive must be trimmed in to its maximum to protect the trim cylinders untreated surfaces from fouling.

  • Page 37: Salt Water Operation

    Salt water operation Your Volvo Penta sterndrive is built for operation in either fresh or salt water. If boat is moored for long periods, tilt drive unit out of the water (except during freezing temperatures). When removing the boat from the water, lower drive...

  • Page 38: Transporting On A Trailer

    NOTE! Do not use a wire brush or other steel tools when cleaning, as these may damage the galvanic protection. IMPORTANT! After use in polluted or salt water the entire Volvo Penta sterndrive’s exterior should be rinsed with fresh water.

  • Page 39: 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 q must be carried out by an authorized Volvo Penta Service workshop.
  • Page 40 EVERY 200 OPERATING HOURS OR AT LEAST ONCE A YEAR Spark plugs: Replace ................... page 55 Ignition cables and distributor cap: Check and clean ........page 55 Drive belts: Check .................. page 39–41 Carburetor filter: Check ................page 53 Flame trap: Clean ..................page 51 Seawater pump: Check impeller ..............

  • Page 41: Maintenance And Care

    The following chapter has a maintenance schedule which shows when maintenance operations must be carried out. NOTE! Always use Volvo Penta Original Spare Parts, otherwise you run the risk of losing the original quality of the product, quite literally bit by bit.
  • Page 42 Alternator belt With engine off, check alternator belt deflection mid- way (A) between the circulating pump pulley (1) and the alternator pulley (2). To increase belt tension: Loosen alternator mounting screws and nuts, and pivot alternator away from engine to increase belt tension.
  • Page 43 To increase belt tension: Loosen pump mounting screws. Insert a 1/2 in. breaker bar into the square hole (D) in the pump mounting bracket, and pivot pump away from engine as shown. Never pry against the pump reservoir or pull filler neck. While maintaining pressure on pump, retighten all mounting screws.

  • Page 44: Lubrication System

    The oil is cooled in the oil cooler (not all models) and cleaned in the oil filter. Al- ways use Volvo Penta original oil filters, they have an integral relief valve that allows the oil to by-pass the filter even if the filter is completely clogged.
  • Page 45 Oil and oil filters. Replacement The oil should be changed when the engine is hot. Stop the engine. Suck out oil through the oil scaveng- ing/bilge pipe. WARNING! Hot oil can cause burns. Unscrew the old filter. NOTE! Avoid oil spillage. Check the mating surface of the engine is clean.

  • Page 46: Cooling System

    If overheating still occurs, return to port at low RPM to prevent excessive overheating and engi- ne damage. See your Volvo Penta dealer for service assistance. If there is a risk of frost the cooling system must be drained.
  • Page 47 Starboard Remove one cylinder block drain (C) and clear hole with a wire. Loosen clamp (D) and remove manifold hose. Port Remove one cylinder block drain (E) and clear hole with a wire. Loosen clamp (F) and remove manifold hose. Seawater pump Loosen and slide clamps back.
  • Page 48 Remove and empty the thicker cooling hose (2) from the circulation pump. Remove the drain plug (3) at the exhaust pipe, then clear the hole of any impurities using steel wire so that the water can run out freely. Remove the drain plug (4) from the cylinder block, then clean the drai- nage hole.
  • Page 49 Oil coolers Remove the lower water hose from the oil cooler. If cooler is mounted horizontally, remove either hose, loosen mounting bolt, and tip open end of cooler down to drain. IMPORTANT Failure to completely drain the cooling system will result in serious damage to the engine, exhaust manifolds, pivot housing, and drive unit when temperatures go below freezing.
  • Page 50 Cooling system. Inhibiting When laying up the boat for the winter it is important that the cooling system be flushed with freshwater so that deposits do not dry and to prevent the build-up of salt crystals. Seawater in the system causes cor- rosion when air is introduced and can cause the build-up of salt crystals that could block the system.

  • Page 51: Fuel System

    Check both before and after starting the engine. Run the engi- ne compartment fan for at least 4 minutes before starting the engine. To prevent fire and explosion, Volvo Penta fuel system components meet requirements for fuel and fuel vapour containment. Do not substitute automotive or other non-approved parts.
  • Page 52 If a pump does not operate and/or the engine will not start, check and reset the circuit breaker. See your Volvo Penta dealer if further service is required. 4.3, 5.0, 5.7 IMPORTANT! Do not run engine out of fuel or run the electric fuel pumps dry more than 20 se- conds.
  • Page 53 Flame trap The flame trap (B) should be cleaned annually. Rem- ove flame trap and clean in kerosene or other sol- vent. Blow through with compressed air and check for damage. Reinstall flame trap, check that flame trap is securely mounted. WARNING! To avoid the danger of an explosi- on or fire in the engine compartment, the engine must always have an undamaged flame trap se-...
  • Page 54 4.3, 5.0 and 5.7 models All models have a fuel filter (C) in the fuel line before the fuel pump. IMPORTANT! Volvo Penta EFI engines require a special marine filter with a 5-10 micron filte- ring capability. Do not substitute any other type of filter.
  • Page 55 Carburetor filter GL and GS models A fuel filter is located at the point where the feed pipe connects with the carburetor. Check the filter at least once per season or as necessary. To check: Undo the fuel line and remove the nipple in the filter housing (avoid fuel spillage!).
  • Page 56 It has a memory that stores diagnostic infor- mation in the form of service codes to aid your Volvo Penta dealer when diagnosing performance pro- blems. Contact your Volvo Penta dealer if service is required. NOTE! The electronics in the EEC require protection from false signals and interference.

  • Page 57: Ignition System

    Replace if damaged. Other distributor components are maintenance free. WARNING! To minimize the risk of fire and ex- plosion Volvo Penta ignition components meet safety standards. The use of components that do not meet safety standards (automobile com- ponents for example) can cause a fire or explo- sion on board.
  • Page 58 Firing orders: 3.0 engines 4.3 engines 5.0 and 5.7 engines 1-3-4-2 1-6-5-4-3-2 1-8-4-3-6-5-7-2...

  • Page 59: Electrical Systems

    Electrical systems The electrical system has a voltage of 12 V. The generator has a charging regulator to make it more effective. The engine also has semi-automatic and normal fuses which cut off the current if there is an overload. There are also fuses for the trim pump and the Power Trim controls.
  • Page 60 For the same reason charging circuits must never be switched over while the engine is running. To simul- taneously charge two independent battery circuits, fit a Volvo Penta charge distributor (accessory) to the regular generator. IMPORTANT Turn the engine off and switch off power at the main switches before carrying out work on the electrical system.
  • Page 61 3.0 models Automatic fuse (A) is 50 A and protects the Power Trim pump circuit. Automatic fuse (B) is 50 A and protects the main engine cabling. The fuses are located to starboard of the engine. 4.3 , 5.0 and 5.7 models Automatic fuse (A)* is 50 A and protects the Power Trim pump circuit.
  • Page 62 Battery. Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 63 Battery. Charging WARNING! Danger of explosion! The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxyhydrogen A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good. WARNING! The battery electrolyte contains ex- tremely corrosive sulfuric acid.

  • Page 64: Drive. Sx And Dp-S

    Drive. SX and DP-S Corrosion protection Anodes Sacrificial anodes are attached to the bottom of the gimbal housing (A), at the front (B) of the gearcase above the anti-ventilation plate. Anodes are slowly eroded away by galvanic action and require inspec- tion.
  • Page 65 Active Corrosion-Protection Most boats are equipped with a Volvo Penta Active Corrosion Protection System as standard equip- ment. The system greatly improves the protection and life of the drive unit from corrosion. If your boat does not have this system as standard you can buy it as an accessory.
  • Page 66 Oil level. Check Trim the drive to it's normal running position. Rem- ove the dipstick (A) and check the oil level covers the entire marked area. Add oil if required through the dipstick hole. If oil level is low, add only enough lubri- cant to bring the oil level within the full range of dip- stick.
  • Page 67 Oil. Replacement DP-S drive Place drive unit in the run (down) position. Remove propellers and mounting hardware. See chapter Pro- pellers. NOTE! Removing DuoProp propellers require the use of special tools. Remove the oil drain plug (B) (below propeller shaft) and the oil level dipstick (A).
  • Page 68 WARNING! Removal of the drive requires spe- cial knowledge and tools. A falling drive can cause serious personalinjury. Please contact your nearest authorized Volvo Penta dealer for assistance. IMPORTANT! Failure to lubricate the gimbal bearing and universal joints each year will result in damage to the pivot housing and drive unit.
  • Page 69 Power Trim pump. Oil level SX and DP-S drives At the beginning of each boating season, check the oil level in the reservoir as follows: Trim the drive in as far as possible. Check the oil level is between the MAX and MIN markings on the oil reservoir.
  • Page 70 Because of the special tools required, engine alignment must be performed by a Volvo Penta dealer. IMPORTANT Failure to check engine alignment could result in premature failure of engine coupler, universal joints, and gimbal...

  • Page 71: Steering

    The steering system for your Volvo Penta sterndrive is operated by a steering cable connected to the helm. Restricting movement of the steering cable will limit or stop the steering system’s hydraulic assist.

  • Page 72: Propellers

    See your Volvo Penta dealer for help in determining the correct propeller(s) for your application.
  • Page 73 If the propeller appears damaged, have it checked by your local Volvo Penta dealer. Al- ways carry a spare propeller and replace the dama- ged propeller as soon as possible.

  • Page 74: Propeller Replacement, Sx Drive

    Propeller replacement, SX drive Removal Installation Set the control lever in the NEUTRAL position. WARNING! Make sure the ignition switch is Grease the propeller shaft using water repellant OFF. grease. Set the control lever in the NEUTRAL position. Install the bushing (F) with the inner cone turned Remove the split pin (A) and the locking tab was- toward the propeller shaft cone.

  • Page 75: Propeller Replacement, Dp-S Drive

    Installation Coat the full length of both propeller shafts with WARNING! Ignition switch must be OFF. Volvo Penta propeller shaft grease. Place remote control in the FORWARD position to Place remote control in the FORWARD position to lock propeller shafts.

  • Page 76: Laying Up/Launching

    Maintenance carefully. There you will find the instructions on how to carry out the points recom- mended in the checklist. If there is any item you are not sure of, please contact your Volvo Penta dealer for more information.

  • Page 77: Bringing Out Of Storage

    Bringing out of storage Connect up the charged batteries. Check oil level in the engine and drive/reverse gear. Top up if required. For oil quality: See Paint drive and hull: See following section. chapter Technical Data. Immediately before launching the drive’s sacrifici- NOTE! If there is inhibiting oil in the system drain al anodes must be cleaned off with emery paper.

  • Page 78: Painting The Drive And Keel

    General Most countries have introduced legislation controlling The drive should be painted with Volvo Penta anti- the use of anti-fouling agents. In some cases these fouling to prevent fouling. Apply according to the ins- agents are completely forbidden for use on leisure tructions on the packaging.

  • Page 79: Fault-Tracing

    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 80: Technical Data

    Ignition timing ............–2 ° ATDC ° BTDC (GL, GS) ° BTDC (Gi) Spark plugs P/N: Volvo Penta ....... 3851831 38511831 AC ..........MR43LTS MR43LTS Champion ........RS12YC RS12YC Spark plug gap, mm ..........1.1 (0.045 in) 1.1 (0.045 in) Tightening torques, spark plugs .......
  • Page 81 Firing order ............... 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2 ° ° Ignition timing ............10 BTDC BTDC Spark plugs P/N: Volvo Penta ....... 3851831 3851857 AC ..........MR43LTS — Champion ........RS12YC RS12YC Spark plug gap, mm ..........1.1 (0.045 in) 1.1 (0.045 in) Tightening torques, spark plugs .......
  • Page 82 Firing order ............... 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2 Ignition timing ............8 ° BTDC ° BTDC Spark plugs P/N: Volvo Penta ....... 3851831 3851831 AC ..........MR43LTS MR43LTS Champion ........RS12YC RS12YC Spark plug gap, mm ..........1.1 (0.045 in) 1.1 (0.045 in) Tightening torques, spark plugs .......
  • Page 83 Fuel specification. See chapter Other product information for more information. 3.0GS ..............93 Octane (RON) unleaded fuel** 4.3GL, 4.3GS ............93 Octane (RON) unleaded fuel** 4.3Gi ..............93* Octane (RON) unleaded fuel** 5.0GL ..............93 Octane (RON) unleaded fuel** 5.0Gi ..............93* Octane (RON) unleaded fuel** 5.7GS ..............
  • Page 84 Notes _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________...
  • Page 85 Notes _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________...

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