Volvo Penta 3.0GLP-D Operator's Manual
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Volvo Penta 3.0GLP-D Operator's Manual

Volvo Penta 3.0GLP-D Operator's Manual

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OPERATOR'S MANUAL
3.0GLP-D
4.3GL-E(F), 4.3GXi-F(F), 4.3OSi-F(F)
5.0GL-F(F), 5.0GXi-F(F), 5.0OSi-F(F)
5.7Gi-F(F), 5.7GXi-G(F), 5.7OSi-E(F), 5.7OSXi-E(F)
8.1Gi-G(F), 8.1GXi-F(F), 8.1OSi-C(F)

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Summary of Contents for Volvo Penta 3.0GLP-D

  • Page 1 OPERATOR’S MANUAL 3.0GLP-D 4.3GL-E(F), 4.3GXi-F(F), 4.3OSi-F(F) 5.0GL-F(F), 5.0GXi-F(F), 5.0OSi-F(F) 5.7Gi-F(F), 5.7GXi-G(F), 5.7OSi-E(F), 5.7OSXi-E(F) 8.1Gi-G(F), 8.1GXi-F(F), 8.1OSi-C(F)
  • Page 2 This operator’s manual is available in English. Complete the form at the end of the operator’s manual to order a copy. Diese Betriebsanleitung ist auch auf Deutsch erhältlich. Ein Bestellcoupon ist am Ende der Betriebsanleitung zu finden. Ce manuel d’instructions peut être commandé en français. Vous trouverez un bon de commande à...
  • Page 3 Directive 94/25/EC as amended by 2003/44/EC 3.0 LITRE Engine manufacturer Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé...
  • Page 4 Directive 94/25/EC as amended by 2003/44/EC 4.3 LITRE Engine manufacturer Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé...
  • Page 5 Directive 94/25/EC as amended by 2003/44/EC 5.0 LITRE Engine manufacturer Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé...
  • Page 6 Directive 94/25/EC as amended by 2003/44/EC 5.7 LITRE Engine manufacturer Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé...
  • Page 7 Directive 94/25/EC as amended by 2003/44/EC 8.1 LITRE Engine manufacturer Volvo Penta of the Americas, Inc., 1300 Volvo Penta Drive, Chesapeake, VA 23320, USA Body for exhaust emission assessment Body for sound emission assessment International Marine Certification Institute International Marine Certification Institute Rue Abbé...
  • Page 8 Notes ..................
  • Page 9 1907. Quality, operating reliability, environment as a core value, Volvo demonstrates its and innovation have made Volvo Penta a world leader in the understanding of the environmental impact its products marine engine industry. From engineering design and...
  • Page 10 INSTALLATION INSTRUCTIONS This page with its accompanying instructions is produced for Volvo Penta’s service workshops, boat-builders, machine manufacturers, and other authorized workshops which have personnel with qualified professional training. The installation instructions are only produced for professional use and are not intended for non-professional use.

  • Page 11: Table Of Contents

    Doing Your Own Maintenance and Repairs....19 Steering System Operation ........42 Volvo Action Service (VAS)........19 Twin Unit Steering ............42 Volvo Penta Dealer Network ........19 Power Trim and Tilt Operation ....... 43 Toll-free Dealer Locator Service......19 Volvo Penta on the Internet........19 Power Trim Operation..........43...
  • Page 12 8.1GXi-F(F), 8.1OSi-C(F)........50 Battery Cables............88 Legend of Symbols Used in Engine Diagrams ...50 Batteries and Connections ......... 88 3.0GLP-D ............... 52 Battery Replacement..........90 4.3GL-E, 5.0GL-F........... 54 Multiple Batteries and Selector Switch ....90 4.3GXi-F, 5.0GXi-F, 5.7Gi-F, 5.7GXi-G ....56 Distributor Cap and Rotor...........
  • Page 13 Table of Contents Drive Components (XDP)........108 Propeller Replacement — DP-S .......117 Removing the DP-S Propeller ......117 Drive Unit Lubrication (XDP) ........108 Installing the DP-S Propeller .......117 Checking the Drive Unit Lubricant (XDP) ... 108 Propeller Replacement — XDP ........118 Draining the Drive Unit (XDP) ......
  • Page 14 Notes Table of Contents ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7745887 English 01-2006...

  • Page 15: Safety Information

    Incorrectly performed operations could result in personal injury, damage to property, or harm the engine. Read the operator’s manual carefully before operating or servicing the engine. If anything is unclear, please contact your Volvo Penta dealer for assistance. In the operator’s manual warning texts have the following priority:...

  • Page 16: General Information

    If you do not understand or are uncertain about any belts and cause serious personal injury. operation or information in this owner’s manual, please contact your Volvo Penta dealer. He will be Crushing Force: Heavy objects may break able to help you with an explanation or will demon- loose and fall, causing a crushing blow that strate the operation.

  • Page 17: Safety Precautions (Maintenance And Service)

    Service literature covering more complicated opera- gine components on top of the engine, use a lifting tions is available from your Volvo Penta dealer. Never beam to raise the engine. All chains and cables carry out any work on the engine if you are unsure...

  • Page 18: Fire And Explosion

    Hot Surfaces and Fluids Components in the electrical, ignition, and fuel sys- tems on Volvo Penta products are designed and con- There is always a risk of burns when working with a structed to minimize the risk of fire and explosion.

  • Page 19: Chemicals

    Safety Information Chemicals Lubrication System Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before commencing work on it. Never start or operate the engine with the oil filler cap removed; Most chemicals such as anti-freeze, rust-proofing hot oil could spray out.

  • Page 20: Safety Precautions While Operating The Boat

    Always use fuel recommended by Volvo Penta. The Maneuvering use of lower quality fuels can damage the engine. Poor fuel quality can also lead to higher maintenance Avoid violent and unexpected changes in course and costs.

  • Page 21: Station Wagon" Effect & Carbon Monoxide

    If you suspect that your boat exhibits this “station wag- stall a good quality carbon monoxide detec- on” effect, please contact your Volvo Penta dealer for tor aboard your boat, in accordance with help in achieving the best solution for your boat.

  • Page 22: Safety Checklists

    Safety Information Safety Checklists Planning Your Trip Everyone wants to have a problem-free and pleasant time when they take their boat out. To help you do this, we have provided a pre-journey checklist below. Take extra time to check the engine and its equip- ment and the general maintenance of the boat.

  • Page 23: Basic Safety Rules Of Boating

    Carry a selection of spare parts for the engine. (Volvo Penta’s on-board kit When driving, make sure that all passengers are safe- contains a selection of essential items that a boat ly seated.
  • Page 24 Notes Safety Information ..................

  • Page 25: Introduction

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

  • Page 26: Certified Engines

    • variant. The engine must not be modified in any way except with accessories and service kits Volvo Penta accepts no responsibility or liability for approved by Volvo Penta. any damage or costs arising due to the above. • No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken.

  • Page 27: Power Ratings

    These conditions are propeller installed originally is frequently one that is referred to as ISO 8665. All Volvo Penta engines meet designed to give maximum speed when the boat is the ISO 8665 standard. This ISO standard outlines the new.
  • Page 28 Notes Introduction ..................

  • Page 29: General Information

    VAS coordinator will make all arrangements necessary to get you back un- Your new Volvo Penta marine engine is covered by a derway as soon as possible. limited warranty according to the conditions and in-...

  • Page 30: Informational Decals And Identification Plates

    General Information Informational Decals and Identification Plates The following images provide graphical representations of various engine decals. The areas described are general locations and are intended to be guides only. Engine models and configurations do vary and, depending on the amount of space available, the exact locations of engine decals tend to vary also.

  • Page 31: Identification Numbers

    The Transom Assembly & Drive Unit Stickers shown above 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 32: Owner's Identification Card

    Service, Replacement 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. Also, Volvo Penta marine engines are designed for high operational reliability and a long service life.

  • Page 33: Instrumentation

    Instruments and ignition switches 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 34: Audible Alarm

    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. VPA 7745887 English 01-2006...

  • Page 35: Checking Instruments

    12 V. With the ignition turned off, the voltmeter will not register a charge. 21196 1. 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 recommend that you contact your dealer to have one installed.

  • Page 36: Power Trim/Tilt

    Instrumentation 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 37: Optional Digital Trim Instrument

    Instrumentation Optional Digital Trim Instrument This instrument displays a figure (the angle of the drive to a stationary boat) within a range. • Trim Range–Use trim range for maximum com- fort, under normal operation, from start to maxi- mum speed (maximum range up to 5). •...

  • Page 38: Trim/Tilt Motor Protection

    Check the engine compartment for water leak- age. If there is damage, operate the boat at low RPM and take it to a Volvo Penta dealer for inspection. Operat- ing a damaged unit could cause additional damage and could become very costly to repair. Have neces- sary repairs made immediately.

  • Page 39: Engine Protection Mode

    Instrumentation Engine Protection Mode In a low oil pressure, low voltage, engine overheat, or lack of exhaust cooling water situation, the Electronic Fuel Injection (EFI) system will enter an Engine Protection Mode (EPM). In such cases, if an acoustic alarm has been installed with your engine, the alarm (located beneath the dashboard) will sound to notify you of a malfunction.

  • Page 40: Engine Control Module (Ecm)

    Engine Protection Mode (low oil pressure or en- gine overheat), also called Speed Limited Operator Warning (SLOW), the other engine will follow suit. 23691 Other Instruments See your Volvo Penta dealer for additional accesso- ries specifically designed for your Volvo Penta prod- uct. VPA 7745887 English 01-2006...

  • Page 41: Controls

    The gear shift release, throttle lock, and engine speed control are combined in one lever. The gear shift release 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 42: Twin Unit Maneuvering

    Controls Twin Unit Maneuvering When leaving or approaching the dock, or for any close maneuvering at slow speed, place the port en- gine in neutral, on standby, and use the starboard en- gine with the control nearest the operator. The use of one control is very effective and more convenient.

  • Page 43: Shifting Between Forward And Reverse

    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 could result...

  • Page 44: Friction Brake

    The remote control has a friction brake, which can be adjusted as necessary, to provide lighter or heavier le- ver action. If you are using a Volvo Penta shift control and you wish to make adjustments to the friction brake, follow the instructions below to make the nec- essary changes.

  • Page 45: Trim Controls

    Controls Trim Controls Trimming (raising and lowering the drive) can be per- formed by using: • A separate control panel (4) on the instrument panel. • A control button (5) on the remote control lever. • The control buttons on the port control lever in a twin installation.

  • Page 46: Control Lever With Catch Button (Single)

    Controls Control Lever with Catch Button (Single) A switch on the control lever (6) allows you to trim the drive as follows: • Pressing the switch up moves the drive trim out while raising the boat’s bow. • Pressing the switch down moves the drive trim in while lowering the boat’s bow.

  • Page 47: Operation

    Operation Operation Operating the Engine CAUTION! Do not start the engine out of the water unless you have connected a hose with running water to the flushing adapter. Please refer to the section entitled Engine Flush on page 98 for instruc- tions on attaching and running the engine out of water.

  • Page 48: Starting The Engine (Cold Start)

    Operation 9. Lower the drive unit to normal run position; make sure the water intakes are submerged. There should be no obstructions in the water near the propellers. 22786-1 22392-1 Starting the Engine (Cold Start) GL Models A cold engine may require priming before you can start it.

  • Page 49: Gi, Osi, Gxi & Osxi Models

    Operation Gi, OSi, GXi & OSXi Models 1. Move the control handle to the NEUTRAL detent position. 2. Turn the ignition switch to START (II) and hold, for no longer than ten seconds or until engine starts. If the engine does not start, let go momentarily, then try again.

  • Page 50: Starting The Engine (Warm Start)

    Operation Starting the Engine (Warm Start) 1. Move the control handle to the NEUTRAL detent position. 2. Turn the ignition switch to START (II) and hold, for no longer than ten seconds or until engine starts. If the engine does not start, let go momentarily, then try again.

  • Page 51: Operating Remote Controls

    Operation Operating Remote Controls Familiarize yourself with remote control operations before starting the engine. Using the Gear Shift Release Button Method 1 To disengage the gear shift mechanism on remote controls with a throttle lock: 1. Place the control handle in NEUTRAL. 2.

  • Page 52: Steering System Operation

    Operation Steering System Operation 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. Do not interfere with or restrict steering cable movement through the last 90° of bend at the engine. Do not use cable retainers, clamps, or tie straps.

  • Page 53: Power Trim And Tilt Operation

    Operation Power Trim and Tilt 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. When using the dash mounted switches, the bottom button lowers the bow and the top button raises the bow.

  • Page 54: Determining The Proper Trim

    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 55: Operating In "Bow-Down" Position

    If you ex- perience boat instability and/or high steering torque, see your Volvo Penta dealer to correct these conditions. Power Tilt Operation Tilting is normally used for raising the drive unit to ob- tain clearance when beaching, launching from a trail- er, or mooring.

  • Page 56: Power Trim/Tilt Switch & Gauge Location

    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 oc- curs, see your authorized Volvo Penta dealer. Power Trim/Tilt Switch & Gauge Location The power trim/tilt switch is located on the remote control handle or on the boat’s dashboard.

  • Page 57: Special Boating Situations

    Long term use above altitudes of 5000 ft. may require a change in gear ratio which is not covered under the Volvo Penta Limited Warranty. Volvo Penta carbureted engines may require mechan- ical modifications. See your Volvo Penta dealer for more information.

  • Page 58: Operating In Freezing Temperatures

    21199 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 as described in the maintenance section of this manual after you use it in polluted or salt water.

  • Page 59: Features

    Your Volvo Penta product consists of three components: the engine, transom shield and the sterndrive. There are certain parts on each component that you, the owner, must take care of to make sure that your Volvo Penta product stays in optimum running condition. The important parts of each component are shown in the illustrations on the following “Features”...

  • Page 60: Gxi-F(F), 4.3Osi-F(F), 5.0Gxi-F(F), 5.0Osi-F(F), 5.7Gi-F(F), 5.7Gxi-G(F), 5.7Osi-E(F), 5.7Osxi-E(F), 8.1Gi-G(F), 8.1Gxi-F(F), 8.1Osi-C(F)

    Features 23672 4.3GXi-F(F), 4.3OSi-F(F), 5.0GXi-F(F), 5.0OSi-F(F), 5.7Gi-F(F), 5.7GXi-G(F), 5.7OSi-E(F), 5.7OSXi-E(F), 8.1Gi-G(F), 8.1GXi-F(F), 8.1OSi-C(F) Trim Down Relay 20 Amp Fuse (Fuel Pump) Trim Up Relay 15 Amp Fuse (Ignition) Starter Relay 5 Amp Fuse (Vessel Switch) Fuel Pump Relay 10 Amp Fuse (Trim Control) Ignition Relay 40 Amp Fuse (Instrument Panel) 15 Amp Fuse (EVC)
  • Page 61 Features THIS PAGE INTENTIONALLY LEFT BLANK VPA 7745887 English 01-2006...

  • Page 62: 3.0Glp-D

    Features 3.0GLP-D 23736 1. Circuit Breaker and Fuses 10. Raw Water Outlet 18. Oil Siphon Tube 2. Oil Fill Cap 11. Raw Water Inlet 19. Starter 3. Carburetor 12. Engine Water Circulation 20. Oil Dipstick Pump 4. Flame Arrestor 21. Exhaust Riser 13.
  • Page 63 Features 23737 23738 VPA 7745887 English 01-2006...

  • Page 64: 4.3Gl-E, 5.0Gl-F

    Features 4.3GL-E, 5.0GL-F 23746 1. Exhaust Overheat Sensors 11. Alternator Belt 20. Running Engine Flush Port 2. Circuit Breaker and Fuses 12. Power Steering Fluid Fill 21. Fuel Pump 3. Flame Arrestor 13. Power Steering Pump 22. Distributor 4. Carburetor 14.
  • Page 65 Features 23747 23748 VPA 7745887 English 01-2006...

  • Page 66: 4.3Gxi-F, 5.0Gxi-F, 5.7Gi-F, 5.7Gxi-G

    Features 4.3GXi-F, 5.0GXi-F, 5.7Gi-F, 5.7GXi-G 23693 1. Exhaust Overheat Sensors 10. Oil Siphon Tube 20. Fuel Pump (Low Pressure) 2. Circuit Breaker and Fuses 11. Automatic Belt Tensioner 21. Fuel Filter 2a. 4.3GXi Only: Circuit Breaker 12. Serpentine Belt 22. Exhaust Riser and Fuses 13.
  • Page 67 Features 23694 23695 VPA 7745887 English 01-2006...

  • Page 68: 4.3Osi-F, 5.0Osi-F, 5.7Osi-E, 5.7Osxi-E, 8.1Osi-C

    Features 4.3OSi-F, 5.0OSi-F, 5.7OSi-E, 5.7OSXi-E, 8.1OSi-C 23739 1. Exhaust Overheat Sensors 11. Automatic Belt Tensioner 22. Exhaust Riser 2. Circuit Breaker and Fuses 12. Serpentine Belt 23. Spark Plugs 2a. 4.3OSi Only: Circuit Breaker 13. Power Steering Fluid Fill 24. Running Engine Flush Port and Fuses 14.
  • Page 69 Features 23740 23695 VPA 7745887 English 01-2006...

  • Page 70: 8.1Gi-G, 8.1Gxi-F

    Features 8.1Gi-G, 8.1GXi-F 23696 1. Exhaust Riser 10. Serpentine Belt 19. Fuel Pump (Low Pressure) 11. Power Steering Fluid Fill 20. Running Engine Flush Port 2. Exhaust Overheat Sensor 12. Power Steering Pump 21. Circuit Breaker and Fuses 3. Oil Fill (Engine) 13.
  • Page 71 Features 23697 23698 VPA 7745887 English 01-2006...

  • Page 72: Gl-Ef, 4.3Gxi-Ff, 4.3Osi-Ff, 5.0Gxi-Ff, 5.0Gl-Ff, 5.0Osi-Ff, 5.7Gi-Ff, 5.7Gxi-Gf, 5.7Osi-Ef, 5.7Osxi-Ef

    Features 4.3GL-EF, 4.3GXi-FF, 4.3OSi-FF, 5.0GXi-FF, 5.0GL-FF, 5.0OSi-FF, 5.7Gi-FF, 5.7GXi-GF, 5.7OSi-EF, 5.7OSXi-EF 18658 23700 1. Engine Coolant Fill Cap 4. Raw Water Inlet 7. Heat Exchanger 2. Engine Coolant Reservoir 5. Raw Water Outlet 8. Heat Exchanger Anode 3. Raw Water Pump 6.

  • Page 73: 8.1Gi-Gf, 8.1Gxi-Ff, 8.1Osi-Cf

    Features 8.1Gi-GF, 8.1GXi-FF, 8.1OSi-CF 18658 23699 1. Engine Coolant Fill Cap 4. Raw Water Pump 7. Heat Exchanger Drain Cap 2. Engine Coolant Reservoir 5. Raw Water Outlet 8. Heat Exchanger 3. Engine Water Circulation 6. Raw Water Inlet 9. Heat Exchanger Anode Pump VPA 7745887 English 01-2006...

  • Page 74: Sx-M Sterndrive

    Features SX-M Sterndrive 22896 1. Oil Fill 3. Anodes 5. Oil Drain 2. Trim Sender 4. Raw Water Intake 6. Propeller VPA 7745887 English 01-2006...

  • Page 75: Dp-S Sterndrive

    Features DP-S Sterndrive 22895 1. Oil Fill 4. Raw Water Intake 7. Front Propeller 2. Trim Sender 5. Oil Drain 3. Anodes 6. Rear Propeller VPA 7745887 English 01-2006...

  • Page 76: Xdp Sterndrive

    Features XDP Sterndrive 23741 1. Oil Fill 4. Raw Water Intake 7. Front Propeller 2. Trim Sender 5. Oil Drain 3. Anodes 6. Rear Propeller 1. A third anode (not shown) is located on the trim cylinder. See “Replacing Sacrificial Anodes (XDP)” on page 111. VPA 7745887 English 01-2006...

  • Page 77: Maintenance Parts List

    Maintenance Parts List Maintenance Parts List Engine Parts & Accessories 23179 23180 23170 23169 23177 3.0 GLP-D 3869304 835440 3851230 3853799 3855104 4.3 GL-E 3869305 835440 3851230 3587597 3862228 4.3 GL-EF 3869349 835440 3851230 3831426 3862228 4.3 GXi-F 3869306 835440 3851230 3587597 3862228...

  • Page 78: Engine Parts & Accessories (Continued)

    Maintentance Parts List Engine Parts & Accessories (Continued) 23185 23184 23171 23179 23172-1 3.0 GLP-D 3869304 3842786 3851857 3854261 3854260 4.3 GL-E 3869305 3842786 3858997 3854311 3854331 4.3 GL-EF 3869349 3842786 3858997 3854311 3854331 4.3 GXi-F 3869306 3842786 3858997 3858977 3859019 4.3 GXi-FF 3869307...

  • Page 79: Engine Parts & Accessories (Continued)

    Maintenance Parts List Engine Parts & Accessories (Continued) 23382 23179 23389 All Engines 3858995 381081 SX/DP-S Drive Parts & Accessories 23250 23249 23246 23244 23180 3868911, 3868912, 3868913, 3868914, 3854130 # (Zn) 3855411 # (Zn) 3869333, 3869334, 3851128 3855610 # (Mg) 3855412 # (Mg) 3854127 DP-S...

  • Page 80: Xdp-B Drive Parts & Accessories

    Maintentance Parts List XDP-B Drive Parts & Accessories 3861636 3861634 23180 22392-2 23773-1 3869151 3861634 # (Zn) 3861636 # (Zn) XDP-B 3869152 3851128 3861583 3861635 # (Mg) 3861633 # (Mg) 3869153 3860419 3862048 22392-2 3869151 3862048 (X-B, X-BLT) XDP-B 3869152 3860419 3862466 (XHP-B, XHP-BLT) 3869153...

  • Page 81: Maintenance

    All Volvo Penta engines have been run for a short time during a final test at the factory. You must follow the engine break-in procedure during the first 20 hours of operation to ensure maximum performance and longest engine life.

  • Page 82: First Two Hours

    Check the oil dipstick. If required add non-synthetic oil, but do not overfill. If the oil level is correct and the condition persists, ask your Volvo Penta dealer to check for possible gauge or oil pump malfunc- tion.

  • Page 83: Final Ten Hours

    To ensure your continued boating enjoyment, we recommend that you return your Volvo Penta product to your Volvo Penta dealer for a 20-hour check. This 20-hour check will prevent a minor problem from getting worse and helps ensure a trouble-free boating season. When servicing your engine, your Volvo Penta dealer will use the...

  • Page 84: Preparing For Boating (Launching)

    Check drive and transom shield anodes. Clean or replace as necessary. Off-Season Storage (Winterization) Be sure that your Volvo Penta equipment is properly prepared for off-season storage. Engine or drive dam- age can result if some simple maintenance steps are overlooked prior to storage.

  • Page 85: Static Water Line

    5. When the static water line does not meet these 2. Place a level on top of transom, measure from specifications, contact your Volvo Penta dealer bottom of level to top of riser (B) and record for information on high rise extension kits. Make measurement.

  • Page 86: Maintenance Schedule

    Maintenance Maintenance Schedule The operation, maintenance, and care of the Volvo Penta engine and power package as outlined in this 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 87 Maintenance ENGINE PACKAGE (CONTINUED) Calendar Frequency OR Operating Hours MAINTENANCE POINT (WHICHEVER COMES FIRST) Once Every Once Every Monthly Yearly 2 Years 3 Years Required Action(s) Refer to Each Important Notes Page Usage Every 50 Every 100 Every 200 Every 300 Hours Hours Hours...
  • Page 88 Maintenance DRIVE/TRANSMISSION PACKAGE (CONTINUED) Calendar Frequency OR Operating Hours MAINTENANCE POINT (WHICHEVER COMES FIRST) Once Every Once Every Monthly Yearly 2 Years 3 Years Required Action(s) Refer to Each Important Notes Page Usage Every 50 Every 100 Every 200 Every 300 Hours Hours Hours...

  • Page 89: Maintenance Of Boat's Systems

    Always read and follow the safety warnings provided in this manual. If you are uncertain about any procedures described in the manual, or you would like to purchase a workshop manual, please contact your Volvo Penta dealer. Engine Exhaust System Periodically inspect the engine exhaust system.

  • Page 90: Drive Unit Bellows

    Maintenance Drive Unit Bellows WARNING! If you work on the drive bellows, secure the drive unit in a raised position in such a way that it cannot fall. A falling drive may cause serious injury. Check the drive unit bellows for fractures and deterioration.

  • Page 91: Pcv Valve

    Maintenance PCV Valve The PCV (Positive Crankcase Ventilation) valve con- trols engine emissions by returning crankcase blowby gases to the engine's intake manifold to be burned. A clogged or stuck PCV valve may result in poor engine performance and stalling. For optimal engine perform- ance, PCV valves should be inspected and replaced according to the maintenance schedule.

  • Page 92: Fuel System

    Maintenance Fuel System DANGER! Gasoline is extremely flammable and highly explosive. ALWAYS turn off the engine before refueling. Do not smoke or al- low open flames or sparks near the boat when adding fuel. When filling the gas tank, ground the tank to the source of gasoline by holding the hose nozzle firmly against the side of the deck filler plate, or ground it in some other...

  • Page 93: Gasoline Containing Alcohol

    After completing service procedures, start engine and check entire fuel system for possible leaks. To prevent fire and explosion, Volvo Penta fuel sys- tem components meet U.S. Coast Guard require- ments for fuel and fuel vapor containment. Do not substitute automotive or other non-approved parts.

  • Page 94: Carburetor (Gl)

    After adding fuel sta- bilizer, the engine should be run for ten minutes to allow stabilized fuel to reach all points of the fuel sys- tem. Fuel stabilizer is available from your Volvo Penta dealer. VPA 7745887 English 01-2006...

  • Page 95: Flame Arrestor

    WARNING! Check fuel pumps (A and B) fre- quently for signs of fuel leakage. If leakage occurs, have the fuel pump serviced immedi- ately by your Volvo Penta dealer. EFI engines have two electric fuel pumps: • A high-pressure pump (A) to supply the fuel injectors.

  • Page 96: Fuel Filter

    Operating the engine with a restricted filter may damage the pressure regulator or 10. Clean up the bilge until fuel cannot be detected fuel pumps. See your Volvo Penta dealer if by smell. the pump makes an unusual noise.

  • Page 97: Fuel Filter Replacement (V6/V8 Carb Engines)

    Maintenance Fuel Filter Replacement (V6/V8 Carb Engines) 1. Turn off the engine. 2. Unscrew fuel filter (A), remove, and discard. 3. Lightly lubricate the gasket and inner seal on new fuel filter. 4. Screw on fuel filter and hand-tighten, following instructions on filter.

  • Page 98: Electrical System

    EFI engines. A deep cycle battery, while it may have enough cold cranking amps (CCA), will cause problems with EFI engines. The correct starting battery for all Volvo Penta EFI engines is a standard marine battery with a minimum of 650 CCA and a minimum of 135 minutes reserve capacity.
  • Page 99 Maintenance • The battery used to start the engine must be a 12-volt, heavy duty marine battery, with ade- quate amperage for the engine model installed on your boat. Refer to the section entitled Tech- nical Data on page 131 for the correct battery sizes.

  • Page 100: Battery Replacement

    5. Make sure the ignition switch is OFF before removing or installing electrical equipment, checking any electri- cal connections, or installing battery cables. Multiple Batteries and Selector Switch See your Volvo Penta dealer for multiple battery in- stallation recommendations. If your boat is equipped with multiple batteries and a selector switch, the engine should be operated with the selector switch set to the ALL position.

  • Page 101: Spark Plugs

    Maintenance Spark Plugs Before installing new spark plugs, always check for proper type and gap . Incorrect spark plugs can cause operational problems and possible internal engine damage. Before installing a spark plug, the spark plug seat in the cylinder head should be wiped clean. Tighten plugs to the proper torque value .

  • Page 102: Circuit Breakers And Fuses

    See your Volvo Penta 8. When spark plugs have been thoroughly cleaned, dealer. carefully inspect them for cracks or other defects...

  • Page 103: Belt Adjustments

    However, at least once per year, have your Volvo Penta dealer check the serpentine belt for wear or inspect the belt yourself for cracks, check marks, dry rot, exposed cords, oil or grease. An ideal time to perform this check is when you have the gimbal bearing lubricated.

  • Page 104: V-Belt Engines (Gl Models)

    Maintenance V-Belt Engines (GL Models) The following engines use two separate V-belts (pow- er steering pump and alternator) which may occasion- ally have to be adjusted for tension: 4.3GL and 5.0GL. CAUTION! These belts are heavy duty. Do not replace with automotive belts. Following is a description of the dual belt system: A –...

  • Page 105: Power Steering Pump Belt (Gl Models)

    Maintenance Power Steering Pump Belt (GL Models) NOTE! Improper power steering belt adjustment will result in hard steering. With engine OFF, check power steering pump (2) belt deflection midway between the circulating pump pul- ley and the power steering pump pulley (position E on previous image).

  • Page 106: Cooling System

    Maintenance Cooling System Raw Water System Various Volvo Penta engines have a thermostat-con- trolled raw water cooling system. 1. Cool water is drawn in through raw water intake (A) by an impeller (C) connected to the raw water pump (D) mounted on the front of the engine.

  • Page 107: Engine Overheating (Efi Engines)

    Only operate it until you are clear of the emergency and seek a tow to shore. CAUTION! Continuing to operate an over- heating engine will cause engine damage. 7. See your Volvo Penta dealer for assistance. VPA 7745887 English 01-2006...

  • Page 108: Engine Flush

    Maintenance Engine Flush Volvo Penta engines incorporate an engine flushing port designed to flush the engine with fresh water while the engine is running. If flushing the engine with the boat in the water, the engine should not be run higher than idle or sea water may be drawn in with the fresh water.

  • Page 109: Draining The Cooling System

    The following steps are very important in protecting your engine from damage in freezing conditions. If unsure of how to perform any of the following steps, see your 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.

  • Page 110: Draining The Closed Cooling System

    Maintenance 4. Crank the engine briefly, (1 or 2 crankshaft revo- lutions) but do not start the engine, to clear the water from the pump. 5. Loosen clamp (C) and remove hose (D) from fuel pump. Allow water to drain from hose. 6.

  • Page 111: 5.0, And 5.7 Liter Engines (F-Series)

    Failure to maintain ade- quate antifreeze may result in engine damage during freezing temperatures. To drain the raw water system of your Volvo Penta en- gine (with factory installed closed cooling): 1. With the engine turned off locate and loosen the lower drain cap from the heat exchanger (1).

  • Page 112: Lubrication System

    Lubrication System Engine/Crankcase Oil To obtain the best engine performance and engine life, Volvo Penta recommends synthetic engine oil labelled for API Service CF/SH, or you may use an engine oil with the recommended quality and viscosity. Engine oils are specified by API service, letter designations, and SAE viscosity numbers.

  • Page 113: Checking Engine Oil Level

    NOTE! You may purchase either a manual or an electric suction pump from any marine sup- ply store or from your Volvo Penta dealer. 5. Dispose of used oil according to any applicable federal, state, and local environmental regula- tions.

  • Page 114: Changing The Oil Filter

    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 or in the spring when preparing to launch for the first time.

  • Page 115: Steering System

    Wipe the dipstick and note the “hot” and “cold” fluid levels. If needed, add Volvo Penta Power Trim/Tilt and Steering Fluid. Do not overfill the pump reservoir. CAUTION! Never fill the steering system with oil of unknown quality.

  • Page 116: Drive Components (Sx/Dp-S)

    Maintenance Drive Components (SX/DP-S) The drive unit is filled at the factory with Volvo Penta Synthetic Gear Oil. Drive Unit Lubrication (SX/DP-S) Checking the Drive Unit Lubricant (SX/DP-S) Every week, check the oil level in the drive unit (if pos- sible, without removing the boat from the water).

  • Page 117: Filling The Drive Unit (Sx/Dp-S)

    2. Remove the oil level plug (3). 3. Fill the drive unit with Volvo Penta GL 5 Synthetic Gear Oil. Fill through the oil drain plug location (B and C; see previous page). Fill slowly to purge air.

  • Page 118: Drive Components (Xdp)

    Maintenance Drive Components (XDP) The drive unit is filled at the factory with Volvo Penta Synthetic Gear Oil. Drive Unit Lubrication (XDP) Checking the Drive Unit Lubricant (XDP) Every week, check the oil level in the drive unit by in- specting the drive oil reservoir.

  • Page 119: Filling The Drive Unit (Xdp)

    1. Remove the two 10mm screws (1) securing the rear cover to access the oil vent plug. 2. Fill the drive unit with Volvo Penta Synthetic Gear Oil. Fill through the oil drain plug location C. Fill slowly to purge air. The drive unit is properly filled when the oil appears at the oil vent hole A.

  • Page 120: Sacrificial Anodes

    Do not paint anodes, 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 and are larger in size.

  • Page 121: Replacing Sacrificial Anodes (Xdp)

    Follow equipment manufacturers rec- ommendations. NOTE! Your Volvo Penta product has been shipped with Aluminum anodes (except the trim cyl- inder anode, which is zinc). Aluminum is ef- fective in both saltwater and in fresh water.

  • Page 122: Active Corrosion Protection System (Sx/Dp-S Only)

    Active Corrosion Protection System (SX/DP-S Only) 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 123 (5) is located near the battery connectors. Broken anode or reference sensor unit. Re- place damaged unit. Follow the installation in- structions included with the replacement unit, or see your authorized Volvo Penta dealer for service. NOTE! The active corrosion protection system is...

  • Page 124: Painting The Drive (Sx/Dp-S Only)

    Follow the label instructions for method applications, drying times, and proper disposal of residual product. 5. Apply finish coat. Volvo Penta Parts Catalogs and the Volvo Penta Parts and Accessories Catalog list part numbers for the finishing products that apply to your Volvo Penta product.

  • Page 125: Painting The Drive (Xdp Only)

    Follow the label instructions for method applications, drying times, and proper disposal of residual product. 4. Apply finish coat. Volvo Penta Parts Catalogs and the Volvo Penta Parts and Accessories Catalog list part numbers for the finishing products that apply to your Volvo Penta product.

  • Page 126: Propeller Care

    A rubber hub in the propeller is the shock absorber that minimizes damage to drive units and engines. If the rubber hub should begin to slip, it can be easily replaced at an authorized Volvo Penta dealer or propeller service station.

  • Page 127: Propeller Replacement - Dp-S

    Maintenance Propeller Replacement — DP-S Removing the DP-S Propeller This procedure requires you to use Volvo Penta spe- cial tools. 1. Ignition switch must be OFF. 2. Make sure the remote control is in FORWARD to lock the propeller shaft.

  • Page 128: Propeller Replacement - Xdp

    Maintenance Propeller Replacement — XDP Removing the XDP Propeller This procedure requires you to use Volvo Penta spe- cial tools. 1. Ignition switch must be OFF. 2. Make sure the remote control is in FORWARD to lock the propeller shaft.

  • Page 129: Boat Bottom

    Boat Bottom Engine Alignment The condition of the boat’s bottom can affect your Because of the special tools required, a Volvo Penta boat’s performance. Marine growth, present in fresh dealer must do the engine alignment. This should be water as well as salt water, will reduce boat speed. A done during off-season storage preparations.

  • Page 130: Replacement Parts

    • Fuel injector O-rings, injector fuel line pressure Failure to use genuine Volvo Penta parts may result in product malfunction and possible injury to the opera- relief valve and caps, fuel reservoir vent hose tor and/or passengers.

  • Page 131: Troubleshooting

    Troubleshooting Troubleshooting Troubleshooting - System Isolation The following troubleshooting guide is provided to help you isolate a malfunction of one or more of your boat’s systems. After determining which systems are affected by the malfunction, refer to the individual system troubleshooting charts to isolate the specific cause.

  • Page 132: Engine Troubleshooting Guides

    Whether servicing the boat’s systems yourself or hav- toms of the trouble to the source, without having to ing your product serviced by a certified Volvo Penta read through and prove every possibility. Much of the dealer, you will need this record of information to iden- information here will be familiar to well informed me- tify potential causes of the malfunction.

  • Page 133: Engine Will Not Crank

    Troubleshooting Engine Will Not Starter Circuit - Check: Crank Battery condition: weak, dead, sulfated, bad cells. Battery cables–for loose or corroded connections. Shorted or open ignition switch. Starter motor and solenoid–for shorts, grounds, or open circuits. Starter assist solenoid/starter relay. Circuit breakers.

  • Page 134: Hard Starting - Cold Engine

    Troubleshooting Hard Starting - Cold Has Engine Always Done This? Check: Engine Carburetor choke operation and adjustment. Ask these questions first: Fuel lines for obstructions. For debris inside fuel tank. See Electrical/Ignition/Fuel Service Manual. Was Engine Unused For A Long Time? Check: For clean carburetor fuel filters.

  • Page 135: Engine Runs Rough

    Troubleshooting Engine Runs Rough If At Slow Speed - Check: Idle speed and idle mixture. If Fuel Injected, see EFI Di- agnostic Manual Engine timing and spark plugs. Fuel pump pressure. Water or contaminants in fuel. Carburetor or manifold vacuum leak. Internal carburetor fuel leak.

  • Page 136: Engine Overheats

    Troubleshooting Engine Noises and Cooling System Vibrations (Cont.) Supply pump. Loose belts and/or pulleys. See Cooling System on page 96. Mountings Loose, broken, or worn engine mounts. Loose lag screws holding mounts to stringer. Crankshaft Balancer or Flywheel Loose bolt(s). Alternator Loose pulley and/or worn bearings.

  • Page 137: Engine Dies Out

    Troubleshooting Engine Dies Out Loss Of Or Out Of Fuel - Check: – – Fuel gauge operation and wiring. Fuel level in tank. Water or debris in fuel. Fuel pickup tube and screen blockage. Fuel tank vent blockage. Plugged external canister or carburetor fuel filters. Air leak on suction side of fuel system.

  • Page 138: Defective Engine Lubricating System

    Troubleshooting Engine Won’t Reach (Cont.) - Check: Operating RPM Carburetor size and type correct for engine. (Cont.) Fuel pump pressure and vacuum. Boat overloaded or load improperly placed. Engine overheating. Engine timing and ignition system operation. Remote control cables and linkage for proper attachment and travel. Defective Engine Engine Components - Check: Lubricating System...

  • Page 139: Low Battery Voltage After Short Storage

    Troubleshooting Low Battery Voltage Engine/Boat Components - Check: After Short Storage All electrical accessories including ignition circuit off. Disconnect main battery negative cable from battery. Connect ammeter or voltmeter in series between negative battery cable and negative battery post: • Meter reading of “0”...
  • Page 140 Notes Troubleshooting ................. . .

  • Page 141: Technical Data

    Engine.......
  • Page 142 Fuel filter......Water separating 10 micron fuel filter, Volvo Penta PN 3862228...
  • Page 143 Drive unit ......
  • Page 144 Drive unit ......Volvo Penta SAE 75W/90 API service GL 5 synthetic gear oil.
  • Page 145 Fuel filter ......
  • Page 146 Drive unit ......
  • Page 147 Drive unit ......Volvo Penta SAE 75W/90 API service GL 5 synthetic gear oil.
  • Page 148 Drive unit ......
  • Page 149 Drive unit ......
  • Page 150 Drive unit ......
  • Page 151 Drive unit ......Volvo Penta SAE 75W/90 API service GL 5 synthetic gear oil.
  • Page 152 Notes Technical Data ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7745887 English 01-2006...

  • Page 153: Metric Conversion Chart

    Metric Conversion Chart Metric Conversion Chart LINEAR ENERGY OR WORK inches X 25.4 = millimeters (mm) foot-pounds X 1.3558 = joules (j) feet X 0.3048 = meters (m) calories X 4.187 = joules (j) yards X 0.9144 = meters (m) Btu X 1055 = joules (j) miles X 1.6093 = kilometers (km) watt-hours X 3500 = joules (j)

  • Page 154: General Torque Specifications

    General Torque Specifications Metric Conversion Chart The following tables provide general torque specifications for a variety of bolt sizes and threads. Unless specific torque values are called out in the instructions, consult this table whenever you are tightening bolts. CAUTION! Always use the specific torque values called out in the procedural steps. In the event that specific torque values are not provided, you may use the values in these tables.

  • Page 155: Index

    Index Index Numerics Control Panel..............35 Controls ................31 Friction Brake ............34 4.3 GL Draining Only ............. 100 Side Mount ..............34 Single Lever ..............31 Top Mount ..............34 Accessories ..............22 Cooling System ............9, 96 Accidents ................. 10 Core Value ACP ................112 Environmental Care .............
  • Page 156 ID Tags................20 Identification Numbers ..........20, 21 Identification Plates ............20 Features ................49 If the Engine Floods ............39 3.0GLP-D ..............52 Gi, OSi, GXi & OSXi Models ........39 4.3GL-E, 5.0GL-F............54 GL Models..............39 4.3GL-EF, 4.3GXi-FF, 4.3OSi-FF, 5.0GXi-FF, Ignition Switch ..............23 5.0GL-FF, 5.0OSi-FF, 5.7Gi-FF,...
  • Page 157 Index Maintenance ..............71 Paint Application (SX/DP-S Only) ........114 Belt Adjustments............93 Paint Application (XDP Only) .........115 Boat Bottom............119 Painting the Drive (SX/DP-S Only) .........114 Cooling System ............96 Painting the Drive (XDP Only)........115 Drive Components (SX/DP-S) ........ 106 Parts Drive Components (XDP) ........
  • Page 158 Voltmeter................23 GL Models ..............38 Volvo Action Service ............19 Warm Start ..............40 Volvo Penta Dealer Network ..........19 Static Water Line ..............75 Volvo Penta on the Internet..........19 Static Water Line Test ............75 Station Wagon Effect and Carbon Monoxide ....11 Steering System .............105...
  • Page 159 ✂ Yes please, I would like an operator’s manual in English at no charge. Publication number: Post or fax this coupon to: 7745887 Name Document & Distribution Center Order Department ARU2, Dept. 64620 Address SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.volvopenta.com/...
  • Page 160 ✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: Franquear o enviar fax a: 7745896 Nombre Document & Distribution Center Order Department ARU2, Dept. 64620 Dirección SE-405 08 Göteborg Suecia Fax: +46 31 545 772 El pedido puede hacerse tam- bién por internet: http://ww w.volvopenta.com/...
  • Page 161 ✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: Stuur of fax de coupon naar: 7745889 Naam Document & Distribution Center Order Department ARU2, Dept. 64620 Adres SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/...
  • Page 162 ✂ Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: Envie o talão pelo correio ou 7745895 um fax para: Nome Document & Distribution Center Order Department Endereço ARU2, Dept. 64620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 A encomenda também pode...
  • Page 164 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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