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This WorkshopManualwUlalert youto certain proceduresthat mustbe donevery carefully, if you ignore this information, youcould...
®injure yourself or peoplearoundyou
®Injure the boatoperator, boat passengers,or people aroundthe boat
®Damagethe Volvo Penta product or its systems
Understandthe following symbolsbefore proceeding: Alerts youto thepossibility of dangerand SafetyWarning identifies informationthat will helppreventinjuries.
Identifies informationthat will helpprevent damageto machinery.
Appearsnext to informationthat controas correct assemblyandoperation of the product.
This WorkshopManualis written for qualified, factory trained service technicians familiar with the useof Volvo Pentaspecial tools.
This WorkshopManualtells you howto correctly maintain and service Volvo Penta products and systems. Whencorrectly serviced, the Volvo Pentaproduct will be reliable andsafe to operate.
WhenVolvo Pentaspecial tools are called for, use them. Wherementioned, the tools are required to perform the service procedure.
if youuse service proceduresor service tools that are not recommendedin this manual YOUALONEmust decide if your actions might injure people or damagethe Volvo Penta product.
General information ...................................
General Engine Mechanical - V6 and V8 Models ...........
3o0GSEngine ..........................................
4.3GL, GSand Gi Engines ..............................
5.7GL, GSand Gi Engines ..............................
5.7GSi Engines .......................................
7.4GL, Gi, GSi and 8.2 GSi Engines .....................
Steering Systems .....................................
Throttle and Shift Control Systems ......................
Cooling Systems ......................................
Engine Removaland installation ........................
Safety ................................................
Thisworkshopmanualis oneof a set of eight that coversVolvoPenta sterndrivemodels.All eightbookscanbeorderedasaset fromVolvoPenta Parts. OrderP/N7797360-0.
Individualworkshopmanualscoveringthesemodelsarealsoavailable. OrderthefollowingpartnumbersfromVolvoPentaParts.
+ P/N 7797361+8 Engine Components
IncJudesinformationonEngineserviceandtroubleshooting;Engineremoval andinstallation; Steeringsystems;ThrottleandShift Controlsystems;and Coolingsystems.
+P/N 7797362-6 Electrical & Ignition System
IncludesserviceandtroubleshootinginformationonCrankingsystems; Chargingsystems;Trim/Tilt electrical systems;Ignition systems;andEngine andInstrumentwiring diagrams.
+P/N 7797363-4 Fuel System
Includesserviceandtroubleshootinginformationonall carburetor,MFIand TBIfuel systemsandrelated components.
° P/N 7797364-2 EFI Diagnostic Manual GM
Containstroubleshootingproceduresfor air ElectronicFuelInjectedGM modelsandrelated components.
*P/N 7797365+9 PJX WaterJet
Containsserviceinformationfor repairandoverhaulof thewaterjetsystem.
e P/N7797366-7 DPX- Workshop Manual
Includesspecificinformationfor repairandoverhaulof theDPXSterndrive andXactTM steeringsystems.
,P/N 7797367-5 SX and DP-S Sterndrives and Transom Shield
IncludesinformationonTransomShield, UpperGearUnit andLowerGear Unitservice;DriveUnitremovamandinstallation;Propellers;andTrim/Tilt hydraulicoperation.
+P/N 7797368-3 SP and DP Workshop Manual
includesUpperGearUnit andLowerGearUnit overhaulprocedures,installation andremoval.
r-N0~ All sterndrive systemsmust be matchedfor either single or dual engineinstallations. Failure to properly matchengine, transombracketand sterndrive witl result in poorboat performance,andrisk or damageto the engineandor drive becauseof incorrect drive gearratio.
Themodelidentification is located on the enginevalve cover, andMUST correspondwith the transombracket andsterndrive numbersas listed in this document.
¯ Engine Model Number r~ [~ E~]
= Transom Bracket Model Number [~ Sterndrive ModelNumber
DRll4! DR4282
Before working on any part of any Volvo Penta® engine, read the section called Safety at the end of this manual.
This service manualcoversVolvoPentaSterndrivemodels.It is divided into sections concerningvarious systemsandassemblies.Refer to the Contents to locate the section coveringthe systemor assemblyrequiring service. Eachsectiontitle pagehasanadditionallisting 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.
Servicerequiredfor VolvoPentaSterndrivesis generallyoneof three ki rids:
Normalcare andmaintenance - which includes putting a newsterndrive into operation,storing engines,lubrication, andcare underspecial operatingconditions suchas salt waterandcold 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.
CompletedisassernbRyandoverhaul- such as major serviceor rebuildinga unit.
It is importantto determinebeforedisassembJyjust whatthe trouble is and howto correct it quickly, with minimumexpenseto the owner.
Whenrepairing anassembly,the mostreliable 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 specia~tools are designedto performservice proceduresuniqueto the productthat cannotbe completedusing tools from other sources. Theyalso speedrepair workto help achieveservice flat rate times. In 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.
Properpreparationis extremelyhelpful for efficient servicework.Aclean workareaat the start of eachjob will minimizetools andparts becoming misplaced.Cleananenginethat is excessivelydirty beforeworkstarts. Cleaningwill occasionallyuncovertrouble sources.Obtaintools, instrumentsandparts neededfor the job beforeworkis started. Interrupting a job to locatespecialtoo{sor repair kits is a needlessdelay.
Z~Useproper lifting and handling equipment. Workingonsterndrives without proper equipmentcancausedamageand personal injury.
Alwaysuseclean fresh fuel whentesting engines.Troublescanoften be tracedto the useof oldor dirty fuel.
Whetherwithin or following the warrantyperiod, VolvoPentahasa constant interest in their products.
nt is anVolvoPentapolicy to providedealerswith service knowledgesothey cangive professional service demandedby today’s consumer.VolvoPenta TrainingCenters,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 servicequestiondoesnot appearto beansweredin this manual,youare invited to write or call the VolvoPentaServiceDepartment for additional help. Alwaysbesureto havecompleteinformationavailable, including enginemodelnumberandserial number.
Besurethat youarefamiliar with the VolvoPentaWarranty.If youhaveany questions, write the VolvoPentaServiceDepartment.If other than genuine VolvoPentareplacementcomponentsor parts are used, Volvo Pentamay refuse subsequentwarrantyc~aimsinvolving that engine.
Whena brand-nameproductor specific tool is called for, anotheritem may beused.However,the substitute musthaveequivalent characteristics, including type, strength, andmaterial. Youmustdetermineif incorrect substitution couldresult in productmalfunctionandpersonalinjury to anyone.Toavoid hazards,equivalent productswhichare usedmustmeetall current u.s. coast GuardSafety Regulations andABYCstandards.
/~ Whenreplacementparts are required, always use genuineVolvo Pentaparts, or parts with equivalentcharacteristics, includingtype, strength, andmaterial. Failure to doso mayresult in productmalfunc= tion andpossibleinjury to the operatorand/orpassengers.
Parts Catalogsare a goodsourceof information for ordering parts. They are NOTa goodsourcefor disassemblyandreassemblyinformation of the engines,sterndrive, or related systems.Theexplodedviewsin the Parts Catalogsare representationsandmaynot reflect details of the actual assembly.TheWorkshopManualhas detailed information and is the ONLY sourceof disassemblyandreassebly information.
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 through anauthorized dealer.
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 tatest productinformationavailableat the timeof printing.
All photographsandillustrations usedin this manuammaynot depict actual modelsor equipment,but are intendedas representative viewsfor referenceonly. Thecontinuing accuracyof this manualcannotbeguaranteed.
Thepurposeof an enginetune-up is to restore powerandperformancethat hasbeenlost throughwearanddeterioration of oneor morecomponents. In the normaloperation of anengine, thesechangescantake place gradually at a numberof points. It is seldomadvisableto attemptimprovementin performanceby correcting oneor twoitems only. Lastingresults will be obtainedby following a definite andthoroughprocedureof analysis and correcting all items affecting powerandperformance.
Economical,dependableoperation canbe ensuredif a completetune up is performedonceevery boating season,preferably at the beginningof the seasonwhenthe boat is broughtout of off seasonstorage.
Componentsthat affect powerandperformancecan bedivided into three groups:
® Componentsaffecting compression
® Componentsaffecting ignition
,, Componentsaffecting fuel system
Proceduresfor performinga completeenginetune-up will becoveredin this manual.
1. CompressionCheck:Propercompressionis essential for goodengine performance. Anenginewith low or unevencompressioncannot be properly tuned.
/~Use extremecare around engine while running or cranking. Remove loose clothing andjewelry to prevententanglementwith rotating pulleys anddrive belts.
a. Runengineupto normaloperating temperature. N[N-o-te---] EnginemustNOTbestarted andrun withoutwaterfor cooling.
b. Removeany foreign matter from around spark plugs by blowing out with compressedair.
c. Removeandinspect all sparkplugs. Install thread-type compressiongaugein spark plug hole.
d. To PreventSparking:
All ModelsExcept 5.7 GL, GSand 7.4 GL: Remove (grey) 2-wire connector, with purple andgrey wires, at ignition coil.
¯
5.7 GLandGSModelsOnly: Removeboth distributor primary wires from the ignition coil Tapewire terminals to prevent accidental grounding.
® 7.4 GLModelsOnly: Remove14-wire connector at ignition module.
e. With choke and/or throttle plates wide open, crank engine through at least four compressionstrokes.
Theindicated compression pressures are considered normal if the lowest reading cylinder is within 75%of the highest.
Example:
If the highest pressure reading was140 PSI, 75%of 140 is 105. Therefore, any cylinder reading less than 105 PSi indicates an improperly seatedvalve, wornvalve guides, piston, cylinder, or worn or broken piston rings. Any cylinder reading 105 PSI or greater is within specifications, andcompressionis considered normal.
If one or morecylinders read low, squirt approximately one tablespoonof engineoil on top of the pistons in the low reading cylinders. Repeatcompressionpressure check on the cylinders.
1. If compressionimprovesconsiderabDy,the piston rings are at fault.
2. if compressiondoesnot improve, valves are sticking or seating poorly, or valve guidesare ,worn.
3. If two adjacent cylinders indicate low compressionpressures and squirting oil on the pistons doesnot increase the compression, the cause maybe a cylinder headgasket leak betweenthe cylinders. This problemcould allow engine oil and/or coolant to enter the cylinders.
It is recommendedthe following quick reference chart be usedwhencheckingcylinder compressionpressures. Thechart hasbeencalculated so that the lowest readingnumberis 75%of the highest reading.
After checkingcylinder compression,repairs should be madeas necessary.Subsequentadjustmentsto an enginethat doesnot haveproper compressionwill not measurablyimproveperformanceor correct operational problems.After verifying compression,checkignition andfuel systemcornponents.
All of the thesecomponentsare not necessarily part of anenginetuneup, but mustbeconsideredwhenattemptingto correct engine/boatperformanceproblems.Repair or replace componentsonly as required.
/W~Donot substitute automotiveparts. VolvoPentamarinecomponentsmeetU.S, CoastGuardRegulationsfor external ignition proof operationandmarineuse. Theuseof automotiveparts mayresult in fire andexplosion,
• 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.