Volvo Penta 4.3 Gi Workshop Manual
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Volvo Penta 4.3 Gi Workshop Manual

Volvo Penta 4.3 Gi Workshop Manual

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Engine Remove and Install
2(0)
All Gasoline Engines

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Summary of Contents for Volvo Penta 4.3 Gi

  • Page 1 Workshop Manual Engine Remove and Install 2(0) All Gasoline Engines...
  • Page 2 Copyright © 2007 Volvo Penta of the Americas, Inc. All rights reserved. This publication may not be copied, photocopied, reproduced, or converted to any electronic or machine-readable form in whole or in part without the express written consent from Volvo Penta of the Americas, Inc.
  • Page 3 Model Identification ....1 General Information ....3 Metric Conversion Chart .
  • Page 4 Notes ......................
  • Page 5 Volvo Penta engines, transmissions, transom shields, and drives. All sterndrive system components must be matched for either single or dual engine installations. Failure to properly match engine, transmission, transom shield, and drive unit will result in poor boat performance, and risk damage to engine and drive because of incorrect drive gear ratio.
  • Page 6 Model Identification 50328 The XP transom shield identification plate is located on the inner transom plate, above the steering ram. 50315 PROD. TYPE SER. NO. The identification plate for the SX-A/DPS-A stern- drives is located on the rear of the upper gear, just above the parting line between the upper and lower gear housing.

  • Page 7: Table Of Contents

    General Information General Information Tuning the Engine ........5 Intake Manifold Vacuum Testing .
  • Page 8 Service Policy It is a Volvo Penta policy to provide dealers with service knowledge so they can give professional service demanded by today’s consum- er. The Volvo Penta Training Centers, frequent mailing of Service...

  • Page 9: Tuning The Engine

    General Information Special Service Tools Volvo Penta has specially designed tools to simplify some of the dis- assembly and assembly operations. These tools are illustrated in this Service Manual, in many cases in actual use. All special tools can be ordered from Volvo Penta Parts. Individual purchasers of Service Manuals must order Special Tools through an authorized dealer.
  • Page 10 General Information Visually inspect stern drive unit for leaks, missing parts or other obvious defects. Replace deteriorated parts. Compression check: Proper compression is essential for good engine performance. An engine with low or uneven compres- sion cannot be properly tuned. •...
  • Page 11 General Information pressures. The chart has been calculated so that the lowest reading number is 75% of the highest reading. Compression Pressure Limit in PSI Max. Min. Max. Min. Max. Min. Max. Min. After checking cylinder compression, repairs should be made as necessary.

  • Page 12: Intake Manifold Vacuum Testing

    Repair or replace components only as required. WARNING! Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine com- partment.
  • Page 13 General Information See table and chart below and on the following page for more information. Vacuum Gauge Readings Condition Reading Normal at Idle 14-19 in. Hg. (47-64 kPa) Late Ignition Timing 11-17 in. Hg. (37-57 kPa) Late Valve Timing 8-15 in. Hg. (27-50 kPa). Intake Leak Low but steady reading Normal Acceleration...

  • Page 14: Gasoline Requirements

    86 AKI (89 RON) and lower is considered misuse of the engine and will void the engine warran- ty. Volvo Penta suggests the use of 89 AKI or higher fuels. These fuels have additives that are beneficial to maximum engine performance and long life of service components.

  • Page 15: Crankcase Oil

    NOTICE! The use of multi-viscosity oils, such as 10W-30 or 10W-40, is allowed but not recommended. Draining and Filling the Engine Crankcase If using Volvo Penta Premium Synthetic Engine Oil, drain and refill crankcase every 200 hours of operation or once a year, whichever occurs first.

  • Page 16: Oil Filter

    General Information Check the motor oil level frequently with the dipstick. When oil is to be changed, remove dipstick and withdraw oil from crankcase through withdrawal/dipstick tube. The oil withdrawal tube is provided so oil does not have to be drained into the bilge. Withdraw oil with a suction pump.

  • Page 17: Power Steering

    18 ft. lb. (24 Nm) Power Steering Maintain the level with Volvo Penta Power Trim/Tilt & Steering Fluid. Approved power steering fluids such as GM power steering fluid or Dexron II automatic transmission fluid can also be used. Do not over- fill the pump reservoir.
  • Page 18 General Information Boat manufacturers should follow the gasoline storage mixture sec- tion for testing prior to shipment. Fuel stabilizer can be purchased lo- cally at most marine supply stores. Limited Use If the vessels fuel within the tank(s) will not be consumed within a 30- day period from the time of filling, a gasoline fuel stabilizer must be added as per the manufacturer’s instructions.
  • Page 19 Improper or incomplete draining may result in freeze damage to the engine, manifolds, sterndrive, or other components. Freeze damage is not covered under Volvo Penta’s Limited Warranty. Front Disable ignition system See Engine Compression Testing on page 5.

  • Page 20: Preparation For Boating After Storage

    General Information Reconnect ignition system. Starboard Disconnect and drain large hose at circulation pump Port Remove exhaust manifold drain plug. Clear hole with a small wire to ensure complete drainage. Remove cap from engine flush hose and lower hose into bilge. Preparation for Boating After Storage Install all drain plugs.

  • Page 21: Engine Break-In

    General Information quently to be sure all systems are operating properly. Check for fuel, oil, and water leaks. Engine Break-in All engines have been run for a short period of time as 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 22: Submerged Engine Or Water Ingestion In Cylinders

    General Information Watch oil pressure gauge. If gauge indication drops below the normal operating oil pressure range (See Engine Specifications in the back of this manual.) whenever boat attitude is changed (i.e. turning, climbing on plane, etc.), it may be the oil pickup screen is not covered with oil.

  • Page 23: 20-Hour Check

    Check flame arrestor for proper mounting. Start engine and check complete fuel system for leaks. Lubricate steering cable ram with Volvo Penta grease P/N 828250. Check power steering pump reservoir for correct fluid level on models equipped with power steering. Failure to prop- erly lubricate the steering system could lead to loss of steering control.
  • Page 24 General Information whether loping or rough idle condition is caused by a malfunctioning crankcase ventilation system, perform the following tests. With Engine Idling Remove PCV valve from its mounting, but leave vacuum inlet side connected to hose. If the valve is functioning properly and not plugged, a hissing noise will be heard as air passes through valve.

  • Page 25: Troubleshooting - System Isolation

    General Information Troubleshooting - System Isolation The following is to help you isolate a malfunction of one or possibly several systems. After determining which systems are related to the malfunction, refer to the individual system troubleshooting charts to isolate the specific cause. System Isolation Engine Does not Start Engine should crank at specified RPM.

  • Page 26: Engine Will Not Crank

    General Information Also, many factors will seem insignificant but when you think of it, usually the toughest problem to troubleshoot is caused by the small- est error. The greatest aid to solving a service problem is informa- tion. Start gathering information from the boat operator and write it on his job card or work ticket.

  • Page 27: Hard Starting - Cold Engine

    General Information • Primary circuit wiring from ignition switch to ignition coil/igni- tion module • Secondary circuit wiring from coil to spark plug • Spark plugs for proper gap, fouling, burned electrodes, cracked or dirty insulator • See Electrical/Ignition/Fuel Service Manual •...

  • Page 28: Hard Starting - Hot Engine

    General Information See Electrical/Ignition/Fuel System Service Manual Is This A New Condition? Check: Carburetor choke operation and adjustment Carburetor accelerator pump Fuel system for leaks, dirt, or obstructions Engine timing and ignition system See Electrical/Ignition/Fuel System Service Manual Hard Starting - Hot Engine Ask these questions first: Has Engine Always Done This? Check:...

  • Page 29: Engine Noises And Vibrations

    General Information Internal carburetor fuel leak See Electrical/Ignition/Fuel System Service Manual If At High Speed Check: Air leak on suction side of fuel system Too low octane fuel Ignition system secondary circuit Engine timing Wrong model or size carburetor, improper main jets or power valve, defective secondary fuel circuit, secondary vacuum dia- phragm failure External canister and carburetor fuel filters...

  • Page 30: Engine Overheats

    General Information Crankshaft Balancer or Flywheel Loose bolt(s) Alternator Loose pulley, worn bearings Loose mounting bolts Sterndrive Failed U-joints or gimbal bearing Damaged internal drive components Worn, bent or broken propeller hub or blades Loose, worn or damaged engine coupler Engine Overheats Check: Actual engine temperature by verifying with an accurate ther-...

  • Page 31: Defective Engine Lubricating System

    General Information Carburetor cleanliness and operation See Electrical/Ignition/Fuel System Service Manual Loss Of Ignition Check: Primary and secondary ignition circuits Ignition switch Circuit breakers Wiring between engine and dash Main engine harness wiring See Electrical/Ignition/Fuel Service Manual Engine Stops Or Dies Out Due To Seizure Check: Vertical drive for internal damage Oil pressure gauge and crankcase oil level...

  • Page 32: Low Battery Voltage After Short Storage

    General Information Worn or collapsed oil pump relief valve spring, or foreign mate- rial caught on valve seat Oil pump relief valve plunger loose in cover Damaged filter bypass grommet Clogged oil pickup screen, broken tube or housing Plugged crankshaft or blocked oil galleys Dirty or defective hydraulic lifters, clogged push rod passages Poor quality, incorrect viscosity or quantity of oil Oil level too high - too much oil in the crankcase...
  • Page 33 Metric Conversion Chart Metric Conversion ENERGY OR WORK foot-pounds X 1.3558 = joules (j) Chart calories X 4.187 = joules (j) X 1055 = joules (j) watt-hours X 3500 = joules (j) LINEAR kilowatt - hrs X 3.600 = megajoules (MJ) inches X 25.4 = millimeters (mm)
  • Page 34 Metric Conversion Chart Notes ......................
  • Page 35 The special tools should be used when and as recom- mended. Special Tools Alignment Tool 3851083-0 Universal Handle 3850609-3 Sealants, Lubricants and Adhesives Volvo Penta Gasket Sealing Compound Volvo Penta Grease 3M Adhesive Engine Removal NOTICE! Before removing engine, check engine height. See Determining Minimum Engine Height.
  • Page 36 Engine Removal and Installation NOTICE! All switches must be in the “OFF” position prior to disconnecting the red (positive) and black (negative) cables from the battery. This will safeguard against permanent damage to electrical components. Disconnect Power Steering Lines Disconnect both power steering lines at the steering cylinder. Cover both steering cylinder openings and line fittings to pre- vent fluid loss and entry of contaminants.
  • Page 37 Engine Removal and Installation Disconnect the two-wire trim/tilt motor power connector. Slide the red locking tab to the left to unlock the engine harness connector. Push down on the lock clip and remove the engine harness connector. Disconnect Throttle Cable Remove cotter pin and flat washer (1) from throttle arm.
  • Page 38 Engine Removal and Installation Disconnect Water Hose Loosen clamp and pull water supply hose off transom bracket water tube. Separate Engine Mounts Attach a hoist to lifting brackets of engine. Hoist must have a lifting capacity of at least 1500 lb. (680 kg). Remove and retain both lock nuts (1) and both flat washers (2) from rear engine mounts.
  • Page 39 Engine Removal and Installation Remove and retain lag screws from front engine mounts. If sterndrive was removed, lift engine out of engine compartment. If sterndrive was not removed, lift engine slightly and pull it forward to disengage U-joint shaft and flywheel coupler. With U-joint shaft clear of flywheel coupler, lift engine out of compartment.
  • Page 40 Engine Removal and Installation Secure exhaust pipe to transom bracket with four screws. Tighten to 20-25 ft. lb. (27-34 N•m). Slide exhaust hoses and clamps onto exhaust pipes if they were removed. Install engine. Engine Installation Lower engine into engine compartment: •...
  • Page 41 NOTE! Correct engine alignment is essential to long engine drive-train life. The front engine mounts may need adjustment UP or DOWN to produce correct engine alignment. Use Alignment Tool, Volvo Penta P/N 3851083-0, with Universal Handle, Volvo Penta P/N 3850609-31, to check engine alignment.
  • Page 42 GL and Models: The engine throttle cable anchor block bracket has several sets of anchor block holes. The sets of holes marked with a “V” are used for Volvo Penta engines. The set of holes marked “43” are for 4.3 GL models. Holes marked GL are 5.0GL...
  • Page 43 Engine Removal and Installation Install open end of trunnion in anchor block. Install screw in anchor block and position throttle cable assembly in selected set of holes. Nut must be against the anchor bracket, tighten it securely. Throttle arm connector must have a minimum of 9 full turns or 1/4 in.
  • Page 44 Engine Removal and Installation Connect Power Steering Lines Remove tape or protective cover from small hydraulic hose fit- ting (or unscrew steering line connector) and small steering cyl- inder opening. Install small hose fitting into steering cylinder. 23340 Install large hose fitting into steering cylinder. 23339 Tighten small hose fitting to 10-12 ft.
  • Page 45 Engine Removal and Installation Tighten large hose fitting to 15-17 ft.lb. (20-23 N•m). 23338 Connect Electrical Cables Connect plastic two-wire plug of engine harness to two-wire receptacle of trim/tilt motor. Connectors should lock together. Route trim/tilt cable away from the steering cylinder so it will not get tangeled when the steering is activated.
  • Page 46 Engine Removal and Installation Route the instrument cable plug to join engine cable receptacle on engine. The connector should click when fully engauged. Slide the red locking tab to the right to lock the connectors together. Warning! Ensure cable is routed to prevent cutting or chafing on any sharp or hot object.
  • Page 47 Throttle & Shift Control System Throttle & Shift Control System Removal of SAE Remote Control Cables NOTICE! Should it become necessary to remove or replace the remote control cables, the attachment at the engine and sterndrive is very important. Follow these steps for removal of remote control cables.
  • Page 48 Throttle & Shift Control System 8.1 Liter Carburetted Engines Shift Cable From Sterndrive Remove drive’s rear cover. Remove cotter pin and flat washer from anchor pin. Loosen jam nut on shift cable core wire. VPA 7748109 English 09-2007...
  • Page 49 DP-S propeller applications. Shift cable should “PUSH” for for- ward gear on left-hand rotation SX propeller applications. Throttle cable should “Push” to close for Volvo Penta remote controls. Failure to do so could result in loss of control of the boat and possible injury to the boat occupants.
  • Page 50 Throttle & Shift Control System Return remote control shift handle to the neutral detent position. Measure and record the distance between the mark and end of casing. Mark cable core wire at end of casing with control in the neutral detent position.
  • Page 51 Throttle & Shift Control System Apply a light coat of Volvo Penta Grease to the end of the remote control shift cable casing. Slide shift cable through shift cable tube until it appears on the outside of the transom. For ease of installation of shift cable, turn sterndrive to port.
  • Page 52 Throttle & Shift Control System Insert the shift cable through the pivot housing and drive until the groove in the shift cable housing is aligned with the cable anchor. Slide the anchor clip in, engauging the shift cable anchor groove. WARNING! Ensure the anchor clip is completely engauged with the groove in the shift cable housing.
  • Page 53 Throttle & Shift Control System Remove cotter pin, flat washer, and anchor pin. Thread anchor pin halfway onto remote control cable end. Rotate shift lever back to neutral detent position, then move remote control handle to its neutral detent position. Turn anchor pin IN or OUT until it aligns with center of bell crank slot.
  • Page 54 Throttle & Shift Control System Reinstall rear cover and secure with the original screws. Tighten screws to 108-132 in. lb. (12-15 N•m). Throttle Cable to Engine Determine whether you have a “push-to-close” or “pull-to-close” re- mote control system. Cable attachment point at throttle arm is deter- mined by direction of control cable movement.
  • Page 55 GL Models: The engine throttle cable anchor block bracket has several sets of anchor block holes. The sets of holes marked with a “V” are used for Volvo Penta engines. The set of holes marked “43” are for 4.3 GL models. Holes marked GL are for all 5.0GL...
  • Page 56 Throttle & Shift Control System • contact with moving parts, if the engine is accidentally cranked or started. Move the control handle to the NEUTRAL position. Disconnect the yellow/red lead from the key switch and the yellow/red lead from the instrument wiring harness. To test the continuity, calibrate an ohmmeter on high ohms scale.
  • Page 57 Safety Section Part A Marine Products and Safety of People Who Use Them ..S-2 Sterndrive Shift System ....... . . S-3 Sterndrive Throttle Control System .

  • Page 58: Marine Products And Safety Of People Who Use Them

    Part A - Marine Products and safety of People Who Use Them Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufac- turers are careful to make sure... Product User is informed. . . Products are safe and reliable.

  • Page 59: Sterndrive Shift System

    Sterndrive Shift System The Shift System starts here at the remote control lever..and ends here at the propeller. What's Most Important? . . . Shift mechanism must match When the control lever is in Forward, Neutral or Reverse position .

  • Page 60: Sterndrive Throttle Control System

    Sterndrive Throttle Control System The throttle Control System starts here and the remote control lever ..and ends here on the engine. What's Most Important? When the control lever is moved from Forward (or Reverse) to Neutral ..

  • Page 61: Sterndrive Steering System

    Sterndrive Steering System The Steering System starts here at the helm . . . What's Most Important? . . . and ends here at the propel- ler on the sterndrive The Steering System . . . must be installed properly must be adjusted properly must be lubricated What Could Happen?
  • Page 62 How Can Loss of Steering Control be Minimized? use steering components which meet marine industry (ABYC) standards . . . In pre- Read, understand, and follow manufacturer's instructions. delivery Assemble parts and make adjustments carefully . . . inspection Closely follow the warnings marked with .
  • Page 63 Sterndrive Fuel and Electrical Systems The electrical System begins here at the battery ..and ends here at the carburetor or fuel injectors The fuel system . . . and ends starts here at the fuel here on the en- tank .
  • Page 64 Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard require- ments. Most automotive parts do not, especially electrical components that must meet ignition protec- tion requirements of the U.S. Coast Guard regulations. When nonmetallic parts look to be in poor shape . . . replace them! Torn Boots! Wires Cracked! Cracked Fuel Lines!
  • Page 65 Follow "Starting Procedure" outlined in the operator's manual. Always make sure there are no gasoline fumes in the engine compartment before starting the engine. Open the compartment and use your nose. Don't gamble. Backfire flame arrestor must be in place and securely attached to the air intake. Do not alter the backfire flame arrestor.
  • Page 66 Summing Up Now you know some things that can take the joy out of enjoyable boating. No doubt about it . . . it takes time! Reading and understanding instructions. Reading and understanding warnings marked with . . . Putting parts together correctly . . . Making correct adjustments .

  • Page 67: Marine Products And Safety Of People Who Fix Them

    Part B - Marine Products and Safety of People* Who Fix Them Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you? Mechanics can be hurt while . . . Servicing boats Servicing sterndrives Troubleshooting problems...

  • Page 68: Handling Lead Acid Batteries

    Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . . you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly! When you smell the other gasses in the exhaust, you are inhaling carbon monoxide.

  • Page 69: Gasoline! Handle With Care

    Battery gas is explosive! Never yank cables off While charging or discharging, battery posts. . . it's a sure remember. . . way to make lots of sparks. . .surrounded by bat- tery gas No Smoking No Flames No Sparks After Charging.

  • Page 70: Hazardous Products

    Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled. Matches, cigarettes, torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights (furnace, dryer, water heater) ????????? How many of these are in your area? Hazardous Products...

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