Volvo Penta Fuel System Workshop Manual

Z~ Safety Warning

This WorkshopManualwill alert youto certain proceduresthat mustbe donevery carefully, if youignore this information, youcould...

®injure yourself or peoplearoundyou

®injure the boatoperator, boatpassengers,or people aroundthe boat

®Damagethe Volvo Penta product or its systems

Understandthe following symbolsbefore proceeding:

Z~Safety Warning

Alerts youto thepossibility of dangerand identifies informationthat will helppreventinjuries.

identifies informationthat will helpprevent damageto machinery.

Appearsnextto informationthat controls correct assemblyandoperation of the product.

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

This WorkshopManuaBtells you howto correctly maintain and service Volvo Penta products and systems. Whencorrectly serviced, the Volvo Pentaproduct will be reliable andsafe to operate.

WhenVoUvoPentaspecial tools are called for, use them. Wherementioned, the tools are required to perform the service procedure.

if youuseservice proceduresor service tools that are not recommendedin this manual, YOUALONEmust decide if your actions might injure peopleor damagethe VolvoPenta product.

This workshopmanualis oneof a set of four that coversVolvoPentasterndrive "BY"models.All four bookscanbeorderedasa set fromVolvoPenta Parts. OrderP/N7797450-9.

Individual workshopmanualscoveringthesemodelsarealso available. Orderthe following part numbersfromVolvoPentaParts.

¯P/N 7797451-7 EngineComponents

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

¯ P/N7797452-5Electrical

&Ignition System

IncludesserviceandtroubleshootinginformationonCrankingsystems; Chargingsystems;Trim/Tilt electrical systems;Ignition systems;andEngine andInstrumentwiring diagrams.

,P/N 7797453-3Fuel System

Includesserviceandtroubleshootinginformationonall carburetor,MFIand TBIfuel systemsandrelated components.

¯P/N 7797454-1 EF! Diagnostic Manual GM

Containstroubleshootingproceduresfor all ElectronicFuelinjectedGM modelsandrelated components.

¯ P/N 7797455-8SXand DP-SSterndrives andTransom Shield

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

Steering Manual Manual Manual Manual Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power

Model Number

30GSMBYCCE 30GSMBYCCE 30GSMBYCCE 30GSMBYCCE 30GSPBYCCE 30GSPBYCCE 30GSPBYCCE 30GSPBYCCE

43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GSJBYA 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GIJBYA 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE

50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC

TransomShield

3868844, 3868844 3868845 3868845 3868844 3868844 3868845 3868845 3868844 3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846 3868846 3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846 m 3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846 3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846

Drive Unit 3868895 3868896 3868895 3868896 3868895 3868896 3868895 3868896 3868892 3868893 3868894 3868913 3868914 3868892 3868893 3868894 3868913 3868914 3868694 3868892 3868893 3868913 3868914 3868892 3868893 3868913 3868914 3868694 3868892 3868893 3868913 3868914 3868892 3868893 3868913 3868914 3868891 3868890 3868912 3868913 3868891 3868890 3868912 3868913

(1.97:1) SX-M (2.18:1) SX-M (1.97:1) SX-M (2.18:1) SX-M (1.97:1) SX-M (2.18:1) SX-M (1.97:1) SX-M (2.t8:1) SX-M

(1.66:1) SX-M (1.79:1) SX-M (1.89:1) SX-M (1.95:1) DP-SM (2.32:1) DP-SM (1.66:1) SX-M (1.79:1) SX-M (1.89:1) SX-M (1.95:1) DP-SM (2.32:1) DP-SM

PJX-C1 (1.66:1) SX-M (1.79:1) SX-M (1.95:1) DP-SM (2.32:1) DP-SM {1.66:1) SX-M (1.79:1} SX=M {1.95:1) DP-SM (2.32:1) DP-SM

PJX-C1 (1.66:1) SX-M (1.79:1) SX-M (1.95:1) DP-SM (2.32:1) DP-SM (1.66:1) SX-M (1.79:1) SX-M (1.95:1) DP-SM (2.32:1) DP-SM

(1.60:1) SX-M (1.51:l)SX-M (1.78:1) DP-SM (1.95:1) DP-SM (1.60:1) SX-M (1.51:1) SX-M (1.78:1) DP-SM (1.95:1) DP-SM

DPX385 DPX415

Steering

Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Xact Xact Xact Xact Xact Xact

Model Number

50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE

57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE

74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPSYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE

74GSmPBYCCE 74GSIPBYCCE 74GSIPBYCCE 74GSIPBYCCE

82GSIPBYCCE

82GSIPSYOCE 82GSIPBYCCE

82GSIPBYCCE

DPX385XBYDCE

DPX385XBYDCE

DPX385XBYDCE

DPX415XBYDCE

DPX415XBYDCE

DPX415XBYDCE

TransomShield

3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846 3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846 3868844 3868844 3868844 3868846 3868848 3868846 3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846 3868850 3868850 3868916 3868916 3868850 3868850 3868916 3868916 3868289 3868289 3868289 3868289 3868289 3868289

Drive Unit

3868891 3868890 3868912 3888913 3868891 3868890 3868912 3868913 3868889 3868890 3868912 3868913 3868889 3868890 3868912 3868913 3868889 3868912 3868913 3868889 3868912 3868913 3868889 3868911 3868912 3868913 3888889 3888911 3868912 3868913 3888911 3868912 3868911 3868912 3868911 3868912 3868911 3868912 3868637 3868638 3868639 3868637 3868638 3868639

(1.60:1) SX-M (1.51:1) SX-M (1.78:1) DP-SM (1.95:1) DP-SM (1.60:1) SX-M (1.51:1) SX-M (1.78:1) DP-SM (1.95:1) DP-SM

(1.43:1) SX-M (1.51:1)SX-M (1.78:1) DP-SM (1.95:1) DP-SM (1.43:1) SX-M (1.51:1) SX-M (1.78:1) DP-SM (1.95:1) DP-SM

(1.43:1) SX-M (1.78:1) DP-SM (1.95:11 DP-SM (1.43:1) SX-M (1.78:1) DP-SM (1.95:1) DP-SM

(1.43:1) SX-M (1.68:1) DP-SM (1.78:1) DP-SM (1.95:1) DP-SM (1.43:1) SX-M (1.68:1) DP-SM (1.78:1) DP-SM (1.95:1) DP-SM (1.68:l)DP-SM (1.78:1) DP-SM (1.68:1) DP-SM (1.78:1) DP-SM

(1.68:t) DP-SM (1.78:1) DP-SM (1.68:1) DP-SM (1.78:1) DP-SM

(1.59:1) DPX-S1 (1.68:1) DPX-S1 (1.78:1) DPX-S1

(1.59:1) DPX-S1 (1.68:1) DPX-S1 (1.78:1) DPX-St

Safety Warning

Beforeworkingonanypart of a VolvoPentasterndrive,readthe sectioncalledSafetyat theendof this manual.

This service manualcovers"BY"modelVolvoPentaSterndrives. It is divided into sections concerningvarious systemsandassemblies. Referto the Contentsto locate the sectioncoveringthe systemor assemblyrequiring service. Eachsectiontitle pagehasanadditional listing that will describethesection’scontentsin moredetail. Besure to readthe SafetySectionat the endof this manual,andpayspecial attention to all safety warningsastheyappearthroughoutthe text. Since modelsare subject to changeat any time, somephotosmay not depictactualproduct.

GoodService Practice

Servicerequiredfor anVolvoPentaSternDriveis generallyoneof three kinds:

Normalcareandmaintenance - whichincPudesputting a new stemdriveinto operation,storingengines,lubrication,andcare underspecialoperatingconditionssuchassalt waterandcold weather=

Operatingmalfunctions - dueto improperengineor drive mounting,propellerconditionor size,boatcondition,or the malfunctionof somepart of theengine.Thisincludesengine servicingproceduresto keeptheenginein primeoperating condition.

Completedisassemblyandoverhaul- suchas majorservice orrebuildingaunit.

it is importantto determinebeforedisassemblyjust whatthe trouble is andhowto correct it quickly, with minimumexpenseto the owner.

Whenrepairing an assembly,the mostreliable wayto ensurea good job is to doa completeoverhaulonthat assembly,rather thanjust to replacethe badpart. Wearnot readily apparentonother parts could causemalfunctionsoonafter the repair job. Repairkits andsealkits containall the parts neededto ensurea completerepair, to eliminate guesswork,andto savetime.

Repairtimecanalso be minimizedbythe useof special tools. Volvo Pentaspecial tools are designedto performservice procedures uniqueto the productthat cannotbe completedusingtools fromother sources.Theyalso speedrepair workto help achieveserviceflat rate times. In somecases,the useof substitute tools candamagethe part.

Donot operateengineout of waterevenmomentarily.If operatedin a test tank, usethe propertest wheel.Failure to dosocan damagewater pump,overheatengine, or allow excessiveengine RPM.

Preparationfor Service

Properpreparationis extremelyhelpful for efficient servicework.A cleanworkareaat the start of eachjob will minimizetools andparts becomingmisplaced.Cleananenginethat is excessivelydirty Ic)efore workstarts. Cleaningwill occasionallyuncovertrouble sources. Obtaintools, instrumentsandparts neededfor the job beforeworkis started.Interruptinga jobto locatespecialtools or repairkits is a needlessdelay.

Useproperlifting andhandlingequipment.Workingon sterndrives without properequipmentcancausedamageandpersonalinjury.

Alwaysuseclean, fresh fuel whentesting engines.Troublescanoften betracedto theuse,of oldor dirty fuel.

Service Policy

Whetherwithin or following the warrantyperiod, VolvoPentahasa constantinterest in its products.

It is a VolvoPentapolicy to providedealerswith serviceknowledge sothey cangive professional service demandedby today’s consumer.TheVolvoPentaservice schools,frequentmailing of Service andpartsinformationbulletins, letters andpromotions,specialtools, andthis servicemanualrepresentour continuingefforts to assist dealers in giving consumersthe best andmostpromptservice possible. Thisservicemanualcoversall phasesof servicing a Volvo Pentasterndriveunit. If a servicequestiondoesnotappearto be answeredin this manual,youare invited to write to the VolvoPenta ServiceDepartmentfor additional help. Alwaysbe sure to give complete information, including enginemodelnumberandserial number.

Besurethat youare familiar with the VolvoPentaWarrantystatement. If youhaveanyquestions,write the VolvoPentaServiceDepartment. If other than genuineVolvoPentareplacementcomponentsor parts are used, VolvoPentamayrefuse subsequentwarrantyclaims involvingthat engine.

When a brand-nameproductor specific tool is called for, anotheritem maybe used. However,the substitute musthaveequivalent characteristics, includingtype, strength,andmaterial.Youmustdetermineif incorrect substitution couldresult in productmalfunctionandpersonal injury to anyone.Toavoidhazards,equivalentproductswhichare usedmustmeetall current USCoastGuardSafety Regulationsand ABYCstandards.

Volvo Penta Fuel System Workshop Manual

Full download: http://manualplace.com/download/volvo-penta-fuel-system-workshop-manual/

ReplacementParts

Whenreplacementparts are required, alwaysusegenuineVolvo Pentaparts, or parts with equivalentcharacteristics, includingtype, strength, andmaterial. Failure to dosomayresult in productmalfunction andpossibleinjury to the operatorand/orpassengers.

Parts CataJogs

Parts Catalogscontain explodedviewsshowingthe correct assembly of all parts, aswell asa compaetelisting of thepartsfor replacement. Thesecatalogs are helpful asa referenceduring disassemblyand reassembly,andare available fromVolvoPenta.

Special Service Tools

VolvoPentahasspecially designedtools to simplify someof the disassemblyandassemblyoperations. Thesetools are illustrated in this ServiceManual,in manycasesin actual use=All VolvoPenta special tools canbeorderedfromVolvoPentaGenuineParts division. individual purchasersof ServiceManualsmustorder Special Tools throughanauthorizeddealer.

ProductReferences,illustrations &Specifications

VolvoPentaof the Americasreservesthe right to makechangesat anytime,withoutnotice, in specifications andmodelsandalso to discontinuemodels.Theright is also reservedto changeanyspecificationsor partsat anytimewithoutincurring anyobligation to equip sameon modelsmanufacturedprior to date of suchchange.All information,illustrations andspecificationscontainedin this manual are basedonthe latest productinformationavailableat thetimeof printing. Theright is reservedto makechangesat anytimewithout notice.

All photographsandillustrations usedin this manualmaynot depict actual modelsor equipment,but are intendedasrepresentativeviews for referenceonly. Thecontinuingaccuracyof this manualcannotbe guaranteed.