Volvo Penta BY Models Engine Components Workshop Manual_432112632 – PDF DOWNLOAD

Workshop

Manual Engine Components “BY” Models

C 2(0)

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Safety Warning

This WorkshopIVlanual will alert you to certain proceduresthat mustbe donevery carefully, if you ignore this information, you could...

® injure yourself or people aroundyou

® Injure the boat operator, boat passengers,or people around the boat

® Damagethe Volvo Penta product or its systems

Understand the following symbolsbefore proceeding:

Z~ Safety Warning

Alerts youto the possibility of dangerand identifies information that will help preventinjuries.

Identifies information that will help prevent damageto machinery.

Appearsnext to information that controls correct assembly and operation of the product.

This WorkshopManualis ,written for qualified, factory trained service technicians familiar with the use of Volvo Penta special tools.

This Workshop Manual tells you how to correctly maintain and service Volvo Penta products and systems. Whencorrectly serviced, the Volvo Penta product ,will be reliable and safe to operate.

WhenVolvo Penta special tools are called for, use them. Wherementioned, the tools are required to perform the service procedure.

If you use service proceduresor service tools that are not recommendedin this manual, YOUALONEmust decide if your actions might injure people or damagethe Volvo Penta product.

Thisworkshopmanualis oneof a set of four that coversVolvoPentasterndrive "BY"modelsoArl four bookscanbeorderedas a set fromVolvoPenta Parts. OrderP/N7797450-9.

Individual workshopmanualscoveringthesemodelsarealso available. Orderthe folJowingpart numbersfromVolvoPentaParts.

, PIN 7797451=7EngineComponents

IncludesinformationonEngineserviceandtroubleshooting;Engineremoval andinstallation; Steeringsystems;Throttle andShift Controlsystems;and Coolingsystems.

, PIN7797452=5Electrical &Ignition System

IncludesserviceandtroubleshootinginformationonCrankingsystems; Chargingsystems;Trim/Tilt electrical systems;Ignition systems;andEngine andInstrumentwMngdiagrams.

¯ PIN 7797453-3Fuel System

Includesserviceandtroubleshootinginformationonall carburetor,MFIand TBIfuel systemsandrelated components.

¯ PIN 7797454-1EFI DiagnosticManualGM

Containstroubleshootingproceduresfor all ElectronicFue[injectedGM modelsandrelated components.

¯ PIN 7797455-8SXandDP-SSterndrives and Transom

Shield

Includesinformation onTransomShield, UpperGearUnit andLowerGear Unitservice;DriveUnitremovalandinstallation; Propellers;andTrim/Tilt hydraulicoperation.

This VolvoPentaWorkshopManualis part of a set that coversthe following VolvoPenta"BY"Models

This VolvoPentaWorkshopManualis part of a set that coversthe foUowingVolvoPenta"BY"Models

Gi

GS

GSi

GSi

GSi

EN~All sterndnve systemsmust be matchedfor either single or dual engineinstatmations. Failure to properly matchengine, transombracketand st erndrive will result irl poorboat performance,andrisk or damageto the engineandor drive becauseof incorrect drive gearratio.

Themodelidentificatien is located on the enginevalve cover, andMUST correspondwith the transombracketandsterndrive numbersas listed in this document.

Engine Model Number [~ [~

® Transom Bracket Model NumberE~

o Sterndrive Model NumberE~

DRl14!

DR4282

DR4944

DR2058

DR4957

Safety Warning

Before working on arty part of any Volvo Penta® engine, read the section called Safety at the end of this manual.

Introduction

This service manualcoversVolvoPentaSterndrive models.It is divided into sections concerningvarious systemsandassemblies.Referto the Contents to locate the section coveringthe systemor assemblyrequiring service. Eachsectiontitle pagehasanadditional listing that will describethe section’s contentsin moredetail. Besureto readthe SafetySectionat the endof this manual,andpayspecial attention to all safety warningsas they appearthroughoutthe text. Sincemodelsare subject to changeat anytime, somephotosmaynot depict actual product.

GoodService Practice

Servicerequiredfor VolvoPentaSterndrivesis generallyoneof three ki nds:

Normalcare andmaintenance - whichincludes putting a newsterndrive into operation,storing engines,lubrication, andcare underspecial operatingconditions suchas salt water andcold weather.

Operatingmalfunctions - dueto improperengineor drive mounting,propeller conditionor size, boatcondition, or the malfunctionof somepart of the engine.This includes engineservicing proceduresto keepthe enginein prime operatingcondition.

Completedisassemblyandoverhau| - such as major serviceor rebuildinga unit.

determinebefore disassemblyjust whatthe trouble is and quickly, with minimumexpenseto the owner.

Whenrepairing anassembly,the mostreliabJe wayto ensurea goodjob is to doa completeoverhaulonthat assembly,rather thanjust to replace the badpart. Wearnot readily apparentonother parts could causemalfunction soonafter the repair job. Repairkits andseal kits containall the parts neededto ensurea completerepair, to eliminate guesswork,andto save time.

Repairtime canalso beminimizedby the useof special tools. VolvoPenta special tools are designedto performservice proceduresuniqueto the productthat cannotbe completedusing tools from other sources.TheyaEso speedrepair workto help achieveservice flat rate times. [n somecases,the useof substitute tools candamagethe part.

~Donot operate engine out of water even momentarily. If operatedin test tank, usepropertest wheel.Failure to doso candamage supply pump,overheatengine, or allow excessiveengineRPM.

It is importantto howto correct it

Preparationfor Service

Properpreparationis extremelyhelpful for efficient servicework.Aclean workareaat the start of eachjob will minimizetools andparts becoming misplaced.Cleananenginethat is excessivelydirty beforeworkstarts. CleaningwiJl occasionallyuncovertrouble sources.Obtaintools, instrumentsandparts neededfor the job beforeworkis started. Interrupting a job to locate specialtools or repair kits is a needlessdelay.

~Useproper lifting andhandling equipment.Workingonsterndrive~== without proper equipmentcan causedamageandpersonaUinjury. Alwaysuseclean fresh fuel whentesting engines.Troublescanoften be tracedto the useof old or dirty fuel.

ServicePolicy

Whetherwithin or following the warrantyperiod, VolvoPentahasa constant interest in their products.

It is anVolvoPentapolicy to providedealerswith service knowledgeso they cangive professional service demandedby today’s consumer.VolvoPenta .Training Centers,ServiceBulletins, Letters andPromotions,SpecialTools andthis ServiceManualrepresentthe latest VolvoPentaeffort to assist dealers in giving consumersthe best andmostpromptservice possible. This ServiceManualcoversall phasesof servicing the VolvoPentaSterndrive unit. If a service questiondoesnot appearto beansweredin this manual,youare invited to write or call the VolvoPentaServiceDepartment for additional help. Alwaysbesureto havecompleteinformationavailable, including enginemodeJnumberandserial number.

Besurethat youare ~amiliar with the VolvoPentaWarranty.If youhaveany questions, write the VolvoPentaServiceDepartment.If other thangenuine VolvoPenta replacementcomponentsor parts are used, VolvoPentamay refuse subsequentwarrantyclaimsinvolving that engine.

Whena brand-nameproductor specific tool is called for, anotheritem may beused.However,the substitute musthaveequivalentcharacteristics, including type, strength, andmaterial. Youmustdetermineif incorrect substitution couldresult in productmalfunctionandpersonalinjury to anyone.Toavoid hazards,equivalent productswhichare usedmustmeetall current U.S. CoastGuardSafety Regulations and ABYCstandards.

ReplacementParts

/~ Whenreplacement parts are required, always use genuineVolvo Pentaparts, or parts with equivalentcharacteristics, includingtype, strength, andmaterial. Failure to dosomayresult in productmalfunction andpossibleinjury to the operatorand/orpassengers.

Parts Catalogs

Parts Catalogsare a goodsourceof information for orderingparts. They are NOTa goodsourcefor disassemblyandreassembfyinformation of the engines,sterndrive, or related systems.Theexplodedviewsin the Parts Catalogsare representationsandmaynot reflect detatls of the actual assembly.TheWorkshopManualhas detailed information and is the ONLY sourceof disassemblyandreasseblyinformation.

SpecialService Tools

VolvoPentahasspecially designedtools to simplify someof the disassemblyandassemblyoperations.Thesetools are illustrated in this Service Manual,in manycasesin actual use. All VolvoPentaspecial tools canbe order from VolvoPentaGenuineParts. Individual purchasersof Service Manualsmustorder Special Tools throughan authorized dealer.

ProductReferences,illustrations &Specifications

VolvoPentaof the Americas,Inc. reservesthe right to makechangesat anytime,without notice, in specifications andmodelsandalso to discontinue models.VolvoPentaalso reservesthe right to changeanyspecifications or parts at anytime without incurring anyobligation to equipsameon modelsmanufacturedprior to dateof suchchange.All information, illustrations andspecifications containedin this manualare basedonthe latest productinformationavailableat the timeof printing.

All photographsandillustrations usedin this manualmaynot depict actuat modelsor equipment,but are intendedas representative viewsfor referenceonly. Thecontinuing accuracyof this manualcannotbeguaranteed.

’TuningTheEngine

I hepurposeof anenginetune-upis to restore powerandperformancethat hasbeenlost through wearanddeterioration of oneor morecomponents. tr~ the normaloperationof anengine, thesechangescantake p~aceg~’adJally at a numberof points. It is seldomadvisableto attemptimprovementin performanceby correcting oneor twoitems only. Lasting results will be obtainedby following a definite andthoroughprocedureof analysis and correcting all items affecting powerandperformance.

Economical,dependableoperation canbeensuredif a completetune upis performedonceevery’ boating season,preferably at the beginningof the seasonwhenthe boat is broughtout of off seasonstorage.

Componentsthat affect powerandperformancecanbedivided into three. groups:

Componentsaffecting compression

® Componentsaffecting ignition

® Componentsaffecting fuel system

Proceduresfor performinga completeenginetune-upwill becoveredin this manual.

Engine CompressionTesting

1. CompressionCheck:Propercompressionis essential for goodengine performance.Anengine with low or unevencompressioncannot be properlytuned.

~Useextreme care around engine while running or cranking. Remove; loose clothing andjewelry to prevententanglementwith rotating pulleys anddrive belts.

a. Runengineup to normaloperating temperature.

I~ Engine must NOTbe started and run without water for cooling.

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.