Related Manuals for Volvo Penta 3.0GLP-C
Summary of Contents for Volvo Penta 3.0GLP-C
- Page 1 OPERATOR’S MANUAL 3.0GLP-C 4.3GL-D, 4.3GXi-E, 4.3GXi-EF 5.0GL-E, 5.0GXi-E, 5.0GXi-EF 5.7Gi-E, 5.7Gi-EF, 5.7GXi-F, 5.7GXi-FF 8.1Gi-F, 8.1Gi-FF, 8.1GXi-E, 8.1GXi-EF...
- 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 Dit instructieboek kan worden besteld in het erhältlich. Ein Bestellcoupon ist am Ende der Nederlands.
- Page 3 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 4 Consumer Affairs Department Volvo Penta of the Americas, Inc. 1300 Volvo Penta Drive Chesapeake, Virginia 23320, USA Phone: (757) 436-5100 • Fax: (757) 436-5153 http://www.volvopenta.com Volvo Action Service - North America P.O. Box 26113 Greensboro, North Carolina 27402-6113 Toll Free: (877) 33-PENTA • Phone: (336) 393-4966 http://myactionservice.com/English/VAS_Penta.asp...
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Page 5: Table Of Contents
Owner’s Identification Card ........20 Operating in “Bow-down” Position......41 Service, Replacement Parts, and Accessories ..20 Power Tilt Operation ...........42 Volvo Penta Dealer Network ........20 Power Trim/Tilt Switch & Gauge Location.....42 Toll-free Dealer Locator Service......20 Special Boating Situations ........43 Volvo Penta on the Internet........ - Page 6 Circuit Breakers and Fuses........45 Engine Overheating (Gi & GXi only) ..... 84 Legend of Symbols Used in Engine Diagrams ...45 Engine Overheating (All other Models)....85 3.0GLP-C ............... 46 Engine Flush .............. 85 4.3GL-D, 5.0GL-E ..........48 Draining the Cooling System........86 Raw Water Cooled Engines........
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Page 7: 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: DANGER! Failure to comply with a danger symbol will result in serious injury or death to boat operator, boat occupants, and/or others. -
Page 8: 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 9: 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 10: Fire And Explosion
Components in the electrical, ignition, and fuel sys- There is always a risk of burns when working with a tems on Volvo Penta products are designed and con- hot engine. Beware of hot surfaces. For example: the structed to minimize the risk of fire and explosion. -
Page 11: 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 12: Safety Precautions While Operating The Boat
Maneuvering Always use fuel recommended by Volvo Penta. The use of lower quality fuels can damage the engine. Avoid violent and unexpected changes in course and Poor fuel quality can also lead to higher maintenance gear engagement. -
Page 13: 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 14: 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 15: Basic Safety Rules Of Boating
Carry a selection of spare When driving, make sure that all passengers are safe- parts for the engine. (Volvo Penta’s on-board kit ly seated. Emphasize this especially if you have a contains a selection of essential items that a boat larger, high performance cabin cruiser where one nor- owner should carry at all times. - Page 16 Notes Safety Information ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7743722 English 10-2004...
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Page 17: 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 18: Certified Engines
The servicing of ignition, timing, and fuel injec- variant. tion systems must always be carried out by an Volvo Penta accepts no responsibility or liability for authorized Volvo Penta workshop. any damage or costs arising due to the above. 22771... -
Page 19: 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 20 Notes Introduction ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7743722 English 10-2004...
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Page 21: General Information
If you need a tow, parts, or mechanic, the VAS coordinator will Your new Volvo Penta marine engine is covered by a make all arrangements necessary to get you back un- limited warranty according to the conditions and in- derway as soon as possible. -
Page 22: 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 23: 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 24: Owner's Identification Card
Owner's Registration Card inal replacement parts, test equipment, and special or a print-out of the Volvo Penta computer on-line reg- tools necessary for high quality service and repair istration screen. This provides proof of ownership and work. -
Page 25: 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 26: 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 7743722 English 10-2004... -
Page 27: 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 28: 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 Pro- tection 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 29: Master/Slave Arrangement
Warning (SLOW), the other engine will follow suit. 22803 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 30: Trim Instruments
Instrumentation Trim Instruments The trim instrument indicates the current trim position. Your boat may be equipped with an analog or a digital trim instrument. The SX drive has an analog trim in- strument only. The DP-S drive may have either an an- alog or a digital trim instrument. -
Page 31: Optional Digital Trim Instrument
7 Constant yellow light within range of 2 to 5; flashes yellow when drive moves within trim range and bow is raised. Other Instruments See your Volvo Penta dealer for additional accesso- ries specifically designed for your Volvo Penta prod- uct. VPA 7743722 English 10-2004... -
Page 32: 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 33: 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 34: Twin Unit Maneuvering
Controls Twin Unit Maneuvering When leaving or approaching the dock, or for any close maneuvering at slow speed, place the starboard engine in neutral, on standby, and use the port engine with the control nearest the operator. The use of one control is very effective and more convenient. -
Page 35: Shifting Between Forward And Reverse
Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed 25% lower than maximum RPM at WOT. De- pending on hull type, choice of propeller, load and conditions, etc., the maximum engine speed at top... -
Page 36: 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 37: 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 38: Control Lever With Catch Button (Dual)
Controls Control Lever with Catch Button (Dual) There are two switches on the port control lever (8), which gives you the capability of individual adjustment of the drive trim. • Pressing the switches up moves the drive trim out while raising the boat’s bow. •... -
Page 39: 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 85 for instructions on attaching and running the engine out of water. -
Page 40: Starting The Engine (Cold Start)
CAUTION! Too much priming may flood the en- gine. If the engine fails to start after a few at- tempts, there may be a problem that needs to be addressed. See your authorized Volvo Penta dealer for service. 21181 Gi & GXi Models 1. -
Page 41: Gi & Gxi Models
Operation Gi & GXi Models Advance the control handle to FULL THROTTLE (B) to clear a flooded engine. In this throttle position, with the engine speed below 400 RPM (D–cranking speed), the ECM shuts off the fuel injectors so no fuel is delivered. -
Page 42: 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 43: 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 move- ment through the last 90°... -
Page 44: 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 45: Operating In "Bow-Up" Position
“bow-up” or “bow- down” positions. Boat stability and steering torque can also vary due to changing water con- ditions. If you experience boat instability and/or high steering torque, see your Volvo Penta deal- er to correct these conditions. VPA 7743722 English 10-2004... -
Page 46: Power Tilt Operation
22781 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 47: 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 48: Salt Water Operation
Operation 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 49: 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 50: 3.0Glp-C
Features 3.0GLP-C 22878 1. Circuit Breaker and Fuses 9. Raw Water Pump 17. Fuel Pump and Filter 2. Oil Fill Cap 10. Raw Water Outlet 18. Oil Siphon Tube 3. Carburetor 11. Raw Water Inlet 19. Starter 4. Flame Arrestor 12. - Page 51 Features 22879 22880 VPA 7743722 English 10-2004...
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Page 52: 4.3Gl-D, 5.0Gl-E
Features 4.3GL-D, 5.0GL-E 22875 1. Exhaust Overheat Sensors 11. Alternator Belt 21. Fuel Pump 2. Circuit Breaker and Fuses 12. Power Steering Fluid Fill 22. Distributor 13. Power Steering Pump 23. Spark Plugs 3. Flame Arrestor 4. Carburetor 14. Power Steering Belt 24. - Page 53 Features 22876 22877 VPA 7743722 English 10-2004...
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Page 54: 4.3Gxi-E, 5.0Gxi-E, 5.7Gi-E, 5.7Gxi-F
Features 4.3GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F 22886 1. Exhaust Overheat Sensors 11. Automatic Belt Tensioner 21. Fuel Filter 2. Circuit Breaker and Fuses 12. Serpentine Belt 22. Exhaust Riser 3. Flame Arrestor 13. Power Steering Fluid Fill 23. Spark Plugs 4. Engine Oil Fill Cap 14. - Page 55 Features 22887 22888 VPA 7743722 English 10-2004...
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Page 56: 8.1Gi-F, 8.1Gxi-E
Features 8.1Gi-F, 8.1GXi-E 22892 1. Exhaust Riser 10. Serpentine Belt 19. Fuel Pump (Low Pressure) 2. Exhaust Overheat Sensor 11. Power Steering Fluid Fill 20. Engine Raw Water Flush 3. Oil Fill (Engine) 12. Power Steering Pump 21. Circuit Breaker and Fuses 4. - Page 57 Features 22893 22894 VPA 7743722 English 10-2004...
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Page 58: 4.3Gxi-Ef, 5.0Gxi-Ef, 5.7Gi-Ef, 5.7Gxi-Ff
Features 4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF 18658 22889 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. Heat Exchanger Drain Cap VPA 7743722 English 10-2004... -
Page 59: 8.1Gi-Ff, 8.1Gxi-Ef
Features 8.1Gi-FF, 8.1GXi-EF 18658 22891 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. Water Circulation Pump 6. Raw Water Inlet VPA 7743722 English 10-2004... -
Page 60: 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 7743722 English 10-2004... -
Page 61: 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 7743722 English 10-2004... - Page 62 Notes Features ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7743722 English 10-2004...
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Page 63: Maintenance Parts List
Maintenance Parts List Maintenance Parts List 23179 23180 23170 23169 23177 3.0 GLP-C 3869250 835440 3851230 3853799 3855104 4.3 GL-D 3869251 841750 3851230 3587597 3862228 4.3 GXi-E 3869252 3850559 3851230 3587597 3862228 4.3 GXi-EF 3869253 3850559 3851230 3831426 3862228 5.0 GL-E 3869254 3850559 3851230... - Page 64 Maintentance Parts List 23382 23179 23389 All Engines 3858995 381081 23250 23249 23246 23244 23180 3868889 3868890 3868891 3868892 3868893 3854130 # (Zn) 3855411 # (Zn) 3868894 3851128 3855610 # (Mg) 3855412 # (Mg) 3854127 DP-S 3868895 3586461 # (Al) 3863193 # (Al) 3868896 3868911...
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Page 65: 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 66: 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 67: 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 68: 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 69 Maintenance Function Adjust Check Lubricate Fill Replace Tighten Once per season • • Bellows and clamps, drive unit Exhaust manifold and risers • Distributor cap and rotor • Fuel filter, carburetor • Fuel filter, engine • Fuel system (leakage) • •...
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Page 70: 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 71: 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 72: 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 receive a workshop manual, please contact your Volvo Penta dealer. Engine Exhaust System Periodically inspect the engine exhaust system. -
Page 73: Fuel System
Maintenance Fuel System DANGER! Gasoline is extremely flammable and highly explosive. ALWAYS turn off the engine before fueling. Do not smoke or allow 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 manner. -
Page 74: Gasoline Containing Alcohol
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 7743722 English 10-2004... -
Page 75: Carburetor (Gl)
After completing service procedures, start en- gine 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 76: Electric Fuel Pumps
All models have a fuel filter (C) in the fuel line before the fuel pump. NOTE! Volvo Penta EFI engines require a special marine filter with a 10 micron filtering capa- bility. Do not substitute any other type of fil- ter. -
Page 77: Engine Fuel Filter Replacement
A loud whining noise at idle may be due to a restricted fuel filter causing a noisy fuel pump. Operating the engine with a restricted filter may damage the pressure regulator or fuel pumps. See your Volvo Penta dealer if the pump makes an unusual noise. VPA 7743722 English 10-2004... -
Page 78: 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 79: Electrical System
Maintenance Electrical System The engine’s electrical system features cranking, charging, ignition, and trim/tilt circuits. A battery and all necessary wiring provide power. CAUTION! If electrical connections are re- versed, or wires are disconnected when the key switch is ON or the engine is running, sensitive electrical components may be im- mediately damaged. - Page 80 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.
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Page 81: Battery Replacement
Maintenance DANGER! Failure to follow the safety precau- tions below may result in electrical sparks ig- niting fuel vapors, and thereby causing fire or explosion. 1. Operate boat’s bilge blower for at least 5 minutes. Open engine cover or hatch and check the boat’s bilge area for gasoline fumes. -
Page 82: Multiple Batteries And Selector Switch
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 83: 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 84 Maintenance The spark plug wires are a special resistance 8. When spark plugs have been thoroughly cleaned, type. The core is carbon-impregnated linen. This carefully inspect them for cracks or other defects type wire is superior to copper core wire in its that may not have been visible before cleaning.
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Page 85: Belt Adjustments
The serpentine belt tension is adjusted automatically and requires no tension adjustments. However, at least once per year, have your Volvo Penta dealer check the serpentine belt for wear. An ideal time to have this 21203 check performed is when you have the gimbal bearing lubricated. -
Page 86: V-Belt Engines
Maintenance V-Belt Engines The following engines use two separate V-belts which may occasionally 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 87: Power Steering Pump Belt
Maintenance Power Steering Pump Belt 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 88: Cooling System
Maintenance Cooling System Raw Water System Various Volvo Penta engines have a thermostat-con- trolled 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 89: Engine Overheating (All Other Models)
CAUTION! Continuing to operate an over- heating engine will cause engine damage. 7. See your Volvo Penta dealer for assistance. Engine Flush Volvo Penta engines incorporate an engine flushing port designed to flush the engine with fresh water while the engine is running. -
Page 90: 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 91: Draining The Closed Cooling System
(check antifreeze manufacturer’s instructions). Make sure the antifreeze’s freeze point is adequate for ex- pected 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 end cap from the heat exchanger (1). -
Page 92: Impeller: Checking & Replacing
Maintenance 2. Note the hose orientation on the raw water pump (G). Loosen the hose clamps (2) and remove the hoses (E & H) from the raw water pump. Crank the engine briefly, (1 or 2 crankshaft revolutions) but do not start the engine, to clear the water from the pump. -
Page 93: Power Steering Reservoir Fluid Level
This procedure requires the removal of the drive unit; therefore, your Volvo Penta dealer should do it. An ideal time to have this done is during the winterization process or in the spring when preparing to launch for the first time. -
Page 94: Lubrication System
Maintenance Schedule on page 64 provide detailed information about oil filter type and service intervals. When you add or change engine oil, use Volvo Penta engine oils for gasoline engines. Use the viscosity chart to select the SAE viscosity that matches the temperature range in which you expect to operate. -
Page 95: 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 96: Drive Components
Maintenance Drive Components The drive unit is filled at the factory with Volvo Penta GL 5 Synthetic Gear Oil. 22342 Drive Unit Lubrication Checking the Drive Unit Lubricant Every week, check the oil level in the drive unit (if pos- sible, without removing the boat from the water). -
Page 97: Filling The Drive Unit
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 98: 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 99: Active Corrosion Protection System
Maintenance Active Corrosion Protection System Your boat may be equipped with a Volvo Penta active corrosion protection system (APC). This system oper- ates with very little current drain from the boat’s elec- trical system. It keeps the voltage potential in the area around the drive unit in a range that is not corrosive to aluminum. - Page 100 (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...
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Page 101: Painting The Drive
“smut”. If this happens, sand the surface and disposal of residual product. start over using a different acid cleaner. 5. Apply finish coat. Volvo Penta Parts Catalogs and 7. Rinse with water thoroughly and allow to air dry. the Volvo Penta Parts and Accessories Catalog list part numbers for the finishing products that apply to your Volvo Penta product. -
Page 102: 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 103: Propeller Replacement - Dp-S
2. Make sure the remote control is in FORWARD. 3. Coat the full length of the propeller shaft and the inside of the propeller hub with Volvo Penta pro- peller shaft grease P/N 828250; removal of the propeller will be difficult if this is not done. -
Page 104: 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 105: Replacement Parts
O-rings, fuel pressure regulator, and fuel rails. Failure to use genuine Volvo Penta parts may result in product malfunction and possible injury to the opera- Your Volvo Penta product was designed to operate in tor and/or passengers. - Page 106 Notes Maintenance ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7743722 English 10-2004...
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Page 107: 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 108: 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 109: 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 110: 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 Used For A Long Time? Check: For clean carburetor fuel filters. -
Page 111: 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 112: Engine Overheats
Troubleshooting Engine Noises and Cooling System Vibrations (Cont.) Supply pump. Loose belts and/or pulleys. See Cooling System on page 84. 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 113: 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 114: Engine Won't Reach Operating Rpm
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 115: 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 116 Notes Troubleshooting ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7743722 English 10-2004...
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Page 117: Technical Data
Oil Type Engine ......Volvo Penta Premium engine oil labeled for API Service CF/SH Drive unit . - Page 118 Engine ......Volvo Penta engine oil, or suitable pure synthetic oil alternative with the...
- Page 119 Engine ......Volvo Penta engine oil or suitable pure synthetic oil alternative with min.
- Page 120 Engine ......Volvo Penta engine oil, or suitable pure synthetic oil alternative with the...
- Page 121 Engine ......Volvo Penta engine oil or suitable pure synthetic oil alternative with min.
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Page 122: Technical Data 5.7Gi-E, 5.7Gi-Ef, 5.7Gxi-F, 5.7Gxi-Ff
Engine ......Volvo Penta engine oil or suitable pure synthetic oil alternative with min. - Page 123 Engine ......Volvo Penta engine oil or suitable pure synthetic oil alternative with min.
- Page 124 Notes Technical Data ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7743722 English 10-2004...
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Page 125: Metric Conversion Chart
Metric Conversion Chart Metric Conversion Chart LINEAR ENERGY OR WORK inchesX 25.4= millimeters (mm) foot-poundsX 1.3558= joules (j) feetX 0.3048= meters (m) caloriesX 4.187= joules (j) yardsX 0.9144= meters (m) BtuX 1055= joules (j) watt-hoursX 3500= joules (j) milesX 1.6093= kilometers (km) inchesX 2.54= centimeters (cm) kilowatt - hrsX 3.600= megajoules (MJ) AREA... - Page 126 Notes Metric Conversion Chart ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................VPA 7743722 English 10-2004...
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Page 127: Index
Index Index Numerics Controls ................29 Friction Brake ............32 Side Mount ..............32 4.3 GL Draining Only ............87 Single Lever ..............29 Top Mount ..............32 Cooling System ............7, 84 Accessories ..............20 Core Value Accidents ................8 Environmental Care ............. i ACP ................. 95 Quality ................ - Page 128 Instrument Panel .............. 21 Engine/Crankcase Oil............90 Ignition Switch............21 Instrument Lighting ........... 21 Oil pressure Gauge........... 21 Features ................45 Tachometer............... 21 3.0GLP-C ..............46 Temperature Gauge..........21 4.3GL-D, 5.0GL-E .............48 Voltmeter..............21 4.3GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F.....50 Instrumentation ..............21 4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF....54 Introduction ..............
- Page 129 Index Maintenance Parts List ............ 59 Refueling ................8 Maintenance Schedule ............ 64 Remote Control Lever ............33 Maneuvering ..............8 Remote Control Unit............29 Master/Slave Installation..........25 Removing the DP-S Propeller ..........99 Method................38 Removing the SX Propeller ..........98 Metric Conversion Chart ..........121 Replacement Parts..........20, 59, 101 Multiple Batteries and Selector Switch ......
- Page 130 5.0GL-E ..............116 Voltmeter................21 5.0GXi-E, 5.0GXi-EF ..........117 Volvo Action Service ............17 5.7Gi-E, 5.7Gi-EF, 5.7GXi-F, 5.7GXi-FF....118 Volvo Penta Dealer Network ..........20 8.1Gi-E, 8.1Gi-EF, 8.1GXi-D, 8.1GXi-DF ....119 Volvo Penta on the Internet..........20 Temperature Gauge ............21 Tensioning V-Belts ............83 Tie Rod ................89 Warning Symbols ...............
- Page 131 ✂ Yes please, I would like an operator’s manual in English at no charge. Publication number: Post or fax this coupon to: 7743722 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 132 ✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: Franquear o enviar fax a: 7743726 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://www.volvopenta.com/...
- Page 133 ✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: Stuur of fax de coupon naar: 7743732 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 134 ✂ Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: Envie o talão pelo correio ou 7743733 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...
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Page 136: Ab Volvo Penta
AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...