Volvo Penta 4.3OSi-E User manual

OPERATORS MANUAL
4.3OSi-E, 4.3OSi-EF
5.0OSi-E, 5.0OSi-EF
5.7OSi-D, 5.7OSi-DF
5.7OSXi-D, 5.7OSXi-DF

7742836 07-2003 1
Contents
Introduction
Our core values: Quality, Safety, Environmental
Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Factors that affect engine performance . . . . . . 6
Power ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How load conditions affect the speed of a planing
hull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
“Station Wagon” effect . . . . . . . . . . . . . . . . . . . 6
Your new boat . . . . . . . . . . . . . . . . . . . . . . . . . 7
Boater’s responsibilities . . . . . . . . . . . . . . . . . . 7
Planning your trip . . . . . . . . . . . . . . . . . . . . . . . 7
Safety equipment . . . . . . . . . . . . . . . . . . . . . . . 7
Basic safety rules of boating . . . . . . . . . . . . . . . 7
High performance boat operation . . . . . . . . . . . 8
Product and Application Information . . . . . . . . . 9
General Information
Identification numbers . . . . . . . . . . . . . . . . . . 10
Owner’s identification card . . . . . . . . . . . . . . . 10
Product references, illustrations, and specifica-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Volvo Action Service (VAS) . . . . . . . . . . . . . . .11
Doing your own maintenance and repairs . . . .11
Parts and accessories . . . . . . . . . . . . . . . . . . .11
Volvo Penta dealer network . . . . . . . . . . . . . . 12
Volvo Penta on the Internet . . . . . . . . . . . . . . 12
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3OSi-EF . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0OSi-EF, 5.7OSi-DF, 5.7OSXi-DF . . . . . . 16
4.3OSi-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.0OSi-E, 5.7OSi-D, 5.7OSXi-D . . . . . . . . . . 20
Anodes (“sacrificial”) . . . . . . . . . . . . . . . . . . . . 22
Audible alarm (optional) . . . . . . . . . . . . . . . . . 22
Operation
Engine systems . . . . . . . . . . . . . . . . . . . . . . . 22
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical system . . . . . . . . . . . . . . . . . . . . . . 22
Electronic Fuel Injection (EFI) . . . . . . . . . . . . . 23
Lubrication system . . . . . . . . . . . . . . . . . . . . . 23
Steering system . . . . . . . . . . . . . . . . . . . . . . . 23
Drive components . . . . . . . . . . . . . . . . . . . . . 23
Emergency stop switch . . . . . . . . . . . . . . . . . 23
Engine protection mode (EFI systems) . . . . . . 23
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine instruments . . . . . . . . . . . . . . . . . . . . . 24
Trim instruments . . . . . . . . . . . . . . . . . . . . . . . 24
Analog trim instrument . . . . . . . . . . . . . . . . . . 24
Digital trim instrument (optional) . . . . . . . . . . . 24
Trim/tilt motor protection . . . . . . . . . . . . . . . . . 25
Impact protection . . . . . . . . . . . . . . . . . . . . . . 25
If you strike a solid object: . . . . . . . . . . . . . . . 26
Power trim/tilt . . . . . . . . . . . . . . . . . . . . . . . . . 26
Propellers
Propeller Selection . . . . . . . . . . . . . . . . . . . . . 27
“D” series aluminum propellers . . . . . . . . . . . 27
“F” series stainless steel propellers . . . . . . . 27
“X” series composite propellers . . . . . . . . . . 27
Twin engine installation . . . . . . . . . . . . . . . . . 28
XDP drive unit . . . . . . . . . . . . . . . . . . . . . . . . 28
Remote controls
Trim controls . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operating trim controls . . . . . . . . . . . . . . . . . . 29
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control lever . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control lever (single installation) . . . . . . . . . . . 30
Control lever (twin installation) . . . . . . . . . . . . 30
Engine break-in period . . . . . . . . . . . . . . . . . . 31
First two hours . . . . . . . . . . . . . . . . . . . . . . . . 32
Next eight hours . . . . . . . . . . . . . . . . . . . . . . . 32
Final ten hours . . . . . . . . . . . . . . . . . . . . . . . . 32
First service inspection (Dealer 20-hour check) 32
Start the engine and check that . . . . . . . . . . . 32
Stop the engine and . . . . . . . . . . . . . . . . . . . . 32
Restart the engine and recheck that . . . . . . . . 32
Operating after break-in period . . . . . . . . . . . . 33
Starting the engine, cold start . . . . . . . . . . . . . 33
If the engine floods: . . . . . . . . . . . . . . . . . . . . 33
Starting the engine (warm start) . . . . . . . . . . . 33
If the engine floods: . . . . . . . . . . . . . . . . . . . . 33
Stopping the engine . . . . . . . . . . . . . . . . . . . . 34
Operating remote controls . . . . . . . . . . . . . . . 34
Side mount control . . . . . . . . . . . . . . . . . . . . . 34
Top mount control . . . . . . . . . . . . . . . . . . . . . . 34
Steering system operation . . . . . . . . . . . . . . . 34
Twin unit steering . . . . . . . . . . . . . . . . . . . . . . 34
Power trim and tilt operation . . . . . . . . . . . . . . 35
Power trim operation . . . . . . . . . . . . . . . . . . . 35
Determining the proper trim . . . . . . . . . . . . . . 35
Operating in “bow-up” position . . . . . . . . . . . . 35
Operating in “bow-down” position . . . . . . . . . . 35
Power tilt operation . . . . . . . . . . . . . . . . . . . . . 36
Power trim/tilt switch operation . . . . . . . . . . . . 36
Power trim/tilt switch and gauge location . . . . 37
Shifting and controlling speed . . . . . . . . . . . . . 37
Checking instruments . . . . . . . . . . . . . . . . . . . 38
Special boating circumstances
Engine protection mode operation . . . . . . . . . 39
Shallow water operation . . . . . . . . . . . . . . . . . 39
High altitude operation . . . . . . . . . . . . . . . . . . 39
Operating procedure for freezing temperatures 39
Salt water operation . . . . . . . . . . . . . . . . . . . . 39
Twin engine operation . . . . . . . . . . . . . . . . . . 39
Trailering your boat . . . . . . . . . . . . . . . . . . . . . 40
Propeller selection . . . . . . . . . . . . . . . . . . . . . 40
Maintenance schedule
Preparing for boating after storage (launching) 43
Off-season storage (“winterization”) . . . . . . . . 43
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 43

27742836 07-2003
Contents
Engine exhaust system . . . . . . . . . . . . . . . . . 43
Drive unit bellows . . . . . . . . . . . . . . . . . . . . . . 43
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Gasoline Requirements . . . . . . . . . . . . . . . . . 44
Gasoline Containing Alcohol . . . . . . . . . . . . . . 44
Detonation (spark knock) . . . . . . . . . . . . . . . . 44
Preventing gum formation and corrosion in the
fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electronic fuel injection . . . . . . . . . . . . . . . . . . 44
Flame arrestor . . . . . . . . . . . . . . . . . . . . . . . . 45
Electric fuel pumps . . . . . . . . . . . . . . . . . . . . . 45
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine fuel filter replacement . . . . . . . . . . . . . 45
Electrical system . . . . . . . . . . . . . . . . . . . . . . 46
Battery cables . . . . . . . . . . . . . . . . . . . . . . . . . 46
Batteries and connections . . . . . . . . . . . . . . . 46
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Distributor cap and rotor . . . . . . . . . . . . . . . . . 48
Circuit breakers and fuses . . . . . . . . . . . . . . . 48
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Checking and changing spark plugs . . . . . . . . 49
Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . 51
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine overheating . . . . . . . . . . . . . . . . . . . . . 52
Draining the cooling system . . . . . . . . . . . . . . 53
Engine Flush . . . . . . . . . . . . . . . . . . . . . . . . . 53
Raw Water Cooled . . . . . . . . . . . . . . . . . . . . . 54
Closed Cooling System . . . . . . . . . . . . . . . . . 55
Power trim/tilt fluid level . . . . . . . . . . . . . . . . . 56
Steering system . . . . . . . . . . . . . . . . . . . . . . . 56
Steering reservoir fluid level . . . . . . . . . . . . . . 56
Primary shaft spline lubrication . . . . . . . . . . . . 56
Engine and drive service . . . . . . . . . . . . . . . . 56
Engine/crankcase oil . . . . . . . . . . . . . . . . . . . 57
Checking engine oil level . . . . . . . . . . . . . . . . 57
Changing engine oil . . . . . . . . . . . . . . . . . . . . 58
Changing the oil filter . . . . . . . . . . . . . . . . . . . 58
Drive Components . . . . . . . . . . . . . . . . . . . . . 58
External lubrication points . . . . . . . . . . . . . . . . 58
Lubricating the drive unit (XDP) . . . . . . . . . . . 58
Adding lubricant . . . . . . . . . . . . . . . . . . . . . . . 58
Anodes (“sacrificial” anodes) . . . . . . . . . . . . . 59
Neutra-Salt System
System Operation . . . . . . . . . . . . . . . . . . . . . . 60
Propeller care
Propeller Installation . . . . . . . . . . . . . . . . . . . . 63
D or F-Series . . . . . . . . . . . . . . . . . . . . . . . . 63
X-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Replacement parts . . . . . . . . . . . . . . . . . . . . . 65
Boat bottom . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Bottom painting . . . . . . . . . . . . . . . . . . . . . . . . 65
Engine alignment . . . . . . . . . . . . . . . . . . . . . . 65
Engine submersion . . . . . . . . . . . . . . . . . . . . . 65
Troubleshooting
Problem Resolution . . . . . . . . . . . . . . . . . . . . 67
Warranty information . . . . . . . . . . . . . . . . . . . 67
Warranty Registration Form . . . . . . . . . . . . . . 67
Certified engines . . . . . . . . . . . . . . . . . . . . . . . 68
Bodensee Shiffahrts Ordnung (BSO) number 68
Specifications
4.3 OSi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.0 OSi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.7 OSi/OSXi . . . . . . . . . . . . . . . . . . . . . . . . . 71

7742836 07-2003 3
Introduction
This owner’s manual contains information you need to
operate your boat engine and drive safely. Check that you
have the correct manual for your engine and drive.
This manual also contains a considerable amount of
information concerning the engine and drive: model
identification, preventive maintenance recommendations,
fuel and oil recommendations, and other important points.
Please keep this book with your boat at all times.
NOTE! It is important that this manual stays with the boat
when it is sold. Important safety information must
be passed to the new owner. The service informa-
tion provided in the manual gives the owner impor-
tant information about maintaining the engine and
drive.
If you do not understand or are uncertain about any
operation or information in this owner’s manual, please
contact your Volvo Penta dealer. He will be able to help
you with an explanation or will demonstrate the operation.
NOTE! Federal law requires manufacturers to notify own-
ers in the event that a safety related defect is dis-
covered on any of their products. If you are not the
original owner of this engine and drive, please no-
tify us at our address in the Problem Resolution
section or through an authorized Volvo Penta dealer
about the change in ownership. This is the only way
we will be able to contact you if necessary.
CALIFORNIA
Proposition 65 Warning
Engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive
harm
This manual will alert you to certain things you should do
very carefully. If you don’t, you could
— hurt yourself or bystanders
— hurt the boat operator or bystanders
— damage the machinery.
Carefully observe the safety alert symbols shown for
dangers, warnings, and cautions. They warn you of
possible dangers or important information contained in this
manual.
HOWEVER: Warnings alone do not eliminate hazards,
nor are they a substitute for safe boat handling and
proper accident prevention measures!
DANGER! Failure to comply with a danger symbol
will result in serious injury or death to boat operator,
boat occupants, and/or others.
WARNING! Failure to comply with a warning may re-
sult in injury or death to boat operator, boat occupants
and/or others.
Caution! Failure to comply with a caution may result
in failure or damage to the equipment.

47742836 07-2003
Introduction
Below is a summary of the risks and safety precautions
you should always observe or carry out when operating or
servicing the engine:
1. Check that the warning or information decals on the en-
gine are always clearly visible. Replace decals that have
been damaged or painted over.
2. Always turn the engine off before starting service proce-
dures. Avoid hot surfaces and liquids in supply lines and
hoses when the engine has just been turned off and is
still hot.
3. To prevent a possible explosion, operate the blower as
recommended by the boat manufacturer before starting
the engine. If the engine compartment is not equipped
with a blower, open the engine cover or hatch before
starting to disperse any gasoline fumes that may be
present. Leave the hatch open until after the engine is
running.
4. Reinstall all protective parts removed during service op-
erations before starting the engine. Make a point of fa-
miliarizing yourself with other risk factors, such as rotat-
ing parts and hot surfaces (exhaust manifold, starter, etc.).
5. Approaching a running engine is dangerous. Loose cloth-
ing or long hair can get caught in rotating parts and cause
serious personal injury.
6. If so equipped, turn off the power supply to the engine at
the main switch and lock it in the
OFF position before
starting work.
7. Avoid opening the filler cap for engine coolant system
(freshwater cooled engines) when the engine is still hot.
Steam or hot coolant can spray out as system pressure
is lost.
8. If opening the filler cap or drain cock/venting cock, or
removing a plug or engine coolant line from a hot en-
gine, open the filler cap slowly and release coolant sys-
tem pressure gradually; otherwise, steam or hot coolant
can spray out.
9. Stop the engine and close or block the sea water intake
before carrying out operations on the engine cooling sys-
tem.
10. Only start the engine in a well-ventilated area. If operat-
ing the engine in an enclosed space, make sure your
work area is well ventilated.
11. Anticorrosion and antifreeze agents can be hazardous
to health and to the environment. Whenever you use
these agents, follow the manufacturer’s instructions on
the product packaging.
12. Certain engine oils are flammable. Some of them are also
dangerous if inhaled. Whenever you use these agents,
follow the manufacturer’s instructions on the product pack-
aging. Ensure that ventilation in the work place is good.
Use a protective mask when spraying.
13. Hot oil can cause burns. Avoid skin contact with hot oil.
Ensure that the lubrication system is not under pressure
before beginning to work on it. Never start or operate the
engine with the oil filler cap removed; otherwise, hot oil
could spew out.
14. Never allow an open flame or electric sparks near the
battery or batteries. Never smoke in proximity to the bat-
teries. The batteries give off hydrogen gas during charg-
ing which when mixed with air can form an explosive gas.
This gas is easily ignited and highly volatile. Incorrect
connection of the battery can cause a spark, which would
be sufficient to cause an explosion. Do not disturb bat-
tery connections when starting the engine (spark risk)
and do not lean over batteries.
15. Always ensure that the positive and negative battery leads
are correctly installed on the corresponding terminal
posts. Incorrect installation can result in serious damage
to electrical equipment.
16. Always use protective goggles when charging and han-
dling batteries. Battery electrolyte contains sulfuric acid,
which is highly corrosive. If battery electrolyte comes into
contact with unprotected skin, wash it off immediately
using plenty of water and soap. If battery acid comes in
contact with the eyes, immediately flush with copious
amounts of water and obtain medical assistance.
17. To ensure safe handling and to avoid damaging

7742836 07-2003 5
Introduction
Congratulations on choosing a new boat equipped with a
Volvo Penta marine engine. Volvo Penta has been building
marine engines since 1907. Quality, operating reliability,
and innovation have made Volvo Penta a world leader in
the marine engine industry. From engineering design and
manufacturing to support activities in Parts, Service, and
Sales, high standards have been set to ensure your pride
and satisfaction as the owner of a Volvo Penta product.
As owner of a Volvo Penta marine engine, we would also
like to welcome you to a worldwide network of dealers and
service workshops to assist you with technical advice,
service requirements and replacement parts. Please
contact your nearest authorized Volvo Penta dealer for
assistance.
We wish you many pleasant voyages.
Our core values: Quality, Safety,
Environmental Care
The values and qualities that Volvo Penta expresses are
what make the company unique. From the very beginning,
safety and quality have stood at the heart of the develop-
ment of all of our products, processes, and services. It is
on these values and qualities that the Volvo Penta corpo-
rate identity, brand position and legal status have been
founded. Today’s core values of quality, safety, and care
for the environment remain central to Volvo Penta. They
express what we believe in as a company and will ulti-
mately help us to survive.
Quality is a value that traditionally referred to product
quality but now encompasses all aspects of our products
and services. In today’s competitive environment, Volvo
Penta’s quality commitment extends beyond industrial
craftsmanship and engineering ingenuity to embrace care
for the customer throughout the life of the product.
Safety will always be our most distinguishing core value.
Historically embedded in the quality of all Volvo products, it
also encompasses personal, family, business, and envi-
ronmental values.
Environmental care in all operations, from design to
production, distribution, service, and recycling, is an
integral part of the Volvo quality commitment towards
customers, employees, and the community. By embracing
the environment as a core value, Volvo demonstrates its
understanding of the environmental impact its products
have upon nature and the shared urban and rural sur-
roundings.
Volvo Penta continually commits a considerable part of its
development resources toward minimizing the environ-
mental impact of its products. Examples of areas where we
are always looking for improvements are exhaust emis-
sions, noise levels, and fuel consumption.
Regardless of whether your Volvo Penta engine is in-
stalled in a boat used for pleasure or commercial opera-
tion, incorrect operation or improper maintenance of the
engine will result in disturbance or damage to the environ-
ment.
In this owner’s manual there are a number of service
procedures, which, if not followed, will lead to an increase
in the engine’s impact on the environment, and on running
costs and a reduction in service life. Always observe
recommended service intervals and make a habit of
checking that the engine is operating normally every time
you use it. Contact an authorized Volvo Penta dealer if you
cannot correct the fault yourself.
Remember that most chemicals used on boats are harmful
to the environment if used incorrectly. Volvo Penta recom-
mends the use of biodegradable de-greasing agents for all
cleaning. Always dispose of engine and transmission oil
waste, old paint, de-greasing agents and cleaning residue
etc. at proper disposal areas so that they do not harm the
environment.
Adapt speed and distance during your boat trips so that
swell and noise generated by the boat do not disturb or
harm wildlife, moored boats, docks, etc. Wherever you
land or cruise, please show consideration and always
leave the areas you visit as you would like to find them
yourself.

67742836 07-2003
Introduction
Factors that affect engine
performance
Power ratings
A great number of environmental factors, such as baromet-
ric pressure, ambient temperature, humidity, the quality of
fuel, and exhaust back pressure can affect engine perfor-
mance. When it comes to quoting and comparing ratings, it
is important that there is a unified set of standards for
measurement.
In September 1989, all major marine engine manufactur-
ers agreed to quote engine power output according to a
common set of conditions. These conditions are referred to
as
ISO 8665. All Volvo Penta engines meet the ISO 8665
standard. This ISO standard outlines the following fixed
values or common conditions for determining the rating of
the engine.
Condition .................................................................... Value
Sea Water ........................................................ 77°F (25°C)
Air Temperature ............................................... 77°F (25°C)
Exhaust back-pressure ............................ 1.45 PSI (10kPa)
Barometric pressure .......................... 14.504 PSI (100 kPa)
Relative humidity .......................................................... 30%
A gasoline engine operates with very little surplus air.
When conditions deviate from the standard values, the
result can be a loss of power at full load. It can also cause
a rise in exhaust emissions due to incomplete fuel com-
bustion.
Marine engines can be rated according to one of several
power standards, but power output itself is quoted in
kilowatts (kW) or horsepower (HP), for a given engine
speed, usually at maximum revolutions per minute (RPM).
How load conditions affect the speed of
a planing hull
The overall weight of the boat is another important factor in
performance. Any increase in boat weight will slow down
the boat speed, particularly on boats with planing and
semi-planing hulls.
For example, a new boat tested with fuel and water tanks
only half filled, and without any load, can easily drop 2 to 3
knots in speed when tested fully fuelled and loaded with all
normal equipment and supplies for safe and comfortable
cruising. This is because the propeller installed originally is
frequently one that is designed to give maximum speed
when the boat is new. For this reason it is often advisable
to reduce the propeller pitch by as much as an inch or
more in order to counter the effects of the increase in
overall weight encountered in normal cruising, particularly
in hotter climates. Although this will reduce top speed
somewhat, overall ride conditions will improve and you
should achieve greatly enhanced acceleration.
In considering the influence of weight, it is worth remem-
bering that fiberglass boats absorb a significant amount of
water into their hulls while left afloat for any length of time
and so become progressively heavier. Another negative
influence on boat performance is marine growth beneath
the waterline - a problem that is often overlooked.
“Station Wagon” effect
As long as we continue to use combustion technology for
engines, there will be exhaust emissions. Despite the
substantial reductions achieved in modern engines, as
gasoline burns exhaust emissions and fumes will always
be given off.
But there is also another effect. Any shear-bodied object
moving forward will create a phenomenon we call “Station
Wagon effect.” Due to a difference in air pressure, the
airflow behind such an object will have a tendency to draw
dirt and exhaust emissions back into the object. (You’ll
frequently see evidence of this in the excess of road grime
that is drawn back onto the rear windows of cars.) A boat
with a sheer, broad transom and high superstructure
creates its own station wagon effect. This recirculating air
has a tendency to draw exhaust fumes and water spray up
toward the after-deck. Often people will make the mistake
of opening a ventilator or port hole in order to remove the
fumes, but it has the opposite effect — more fumes are
drawn in, and conditions merely become worse. In high
concentrations these fumes may be hazardous. If you
suspect that your boat exhibits this “station wagon” effect,
please contact your Volvo Penta dealer.
WARNING! Do not run the engine while there are
people located on the swim platform.
DANGER! DO NOT tow anyone using water sports
equipment (such as skis and inner tubes) closer than
ten feet (10’) from the boat. DO NOT, under any circum-
stances, allow people to “teak surf” or “drag surf” using
the swim platform as a means of being pulled along.
Carbon Monoxide poisining may result in serious injury
or death.

7742836 07-2003 7
Introduction
Your new boat
Every new boat has it’s own special characteristics. Even
experienced boat owners should note carefully how a boat
behaves at different speeds, weather conditions, and
loads. Your boat owner’s manual contains information to
help you operate it with safety and pleasure. It contains
details of the boat, equipment supplied or fitted, systems,
and information on operation and maintenance. Please
read it carefully, and familiarize yourself with your boat
before using it for the first time.
We strongly recommend that you install an emergency
stop switch, regardless of the type of boat. If your boat
does not have with an emergency stop switch, contact
your Volvo Penta dealer, who can assist you in selecting
one.
Boater’s responsibilities
The operation, maintenance, and care of the Volvo Penta
engine and power package as outlined in the owner’s
manual are the owner’s responsibility. (See the Mainte-
nance Schedule ) 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. If you are not sure of the proper
maintenance procedures, contact the Volvo Penta Con-
sumer Affairs Department.
The operator is responsible for the correct operation of the
boat and for the safety of all passengers. Make sure that
all operators read this manual before operating the boat.
Show your passengers the location of emergency equip-
ment and explain how to use it. Be sure one of your
passengers knows how to handle your boat in case of
emergency.
Requirements for personal flotation devices (life vests, life
preservers) and other safety equipment vary, depending
on the type of boat and local regulations. Always comply
with the regulations that apply to your boat.
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 equipment and the general
maintenance of the boat.
• Get up to date charts for the planned route
• Calculate distance and fuel consumption
• Note places where you can refuel on your planned course
• Tell friends or relatives about your route (that is, file a
“float plan”).
Safety equipment
• Rescue and emergency items such personal flotation
devices and signal rockets. Make sure all passengers
know where these items are.
• Replacement parts
• Proper tools
• Fire extinguisher checked and charged
Basic safety rules of boating
• Shut off the engine when people who are in the water
come near the boat.
• Propellers are inherently dangerous, and as such are
potential safety hazards. Make sure that the propeller is
not operating when people who are in the water come
near the boat.
• Avoid standing up or shifting weight suddenly in small,
lightweight boats.
• Keep your passengers seated in seats. The boat’s bow,
gunwale, transom, and seat backs are not intended for
use as seats.
• Insist on the use of personal flotation devices by all pas-
sengers at all times.
• Know the “rules of the road” and obey them. If you are
not familiar with the “rules of the road,” take the U.S.
Coast Guard’s boater safety course. You may find infor-
mation about boating safety at
WWW.USCGBOATING.ORG and WWW.CGAUX.ORG/
CGAUXWEB/PUBLIC/PUBFRAME.HTM.
• Prevent explosion and fire by maintaining your fuel de-
livery system in top condition. Fuel vapor is volatile;
handle fuel with care.
• Keep your boat and equipment neat and in top operat-
ing condition. Carry a selection of spare parts for the
engine. (Volvo Penta’s onboard kit contains a selection
of essential items that a boat owner should carry at all
times. See your Volvo Penta dealer.)
•NEVER OPERATE THE BOAT IF YOU ARE UNDER
THE INFLUENCE OF DRUGS OR ALCOHOL.
• If boating waters are unfamiliar, obtain appropriate charts
to avoid damage from underwater objects.

87742836 07-2003
Introduction
High performance boat operation
High performance is not only defined by engine size, but
by a combination of engine power (horsepower), hull
design, and the size of the boat. Your new engine(s)
produce a high power output. Depending on the boat type,
the top speed may be much higher than what you are
accustomed to.
High speed operation requires an experienced operator
who has mastered handling of high performance boats. It
is advisable that you learn the boat’s behavior before you
take passengers on board. Inform your passengers about
your boat’s characteristics and the maneuvers you intend
to do. Use the boat’s performance with due consideration
and care!
When operating at high speeds, remember that other
boaters may not realize the speed at which you are
traveling, especially when you close in on another boat
from astern or from ahead. Always keep a good distance
to allow for the unexpected! Always be prepared for what
other boaters may do unexpectedly. High speed driving
requires the driver to give a high degree of attention to
boat operation and surrounding conditions.
A boat traveling at a speed of approximately 70 MPH (60
knots) covers about 100 feet (30 meters) in 1 second. The
faster you go the quicker things will happen. High speed
driving requires a lot of water and a good distance to
possible hazards! Always allow for adequate reaction time.
Always reduce speed when visibility is reduced for what-
ever reason.
When driving, make sure that all passengers are safely
seated. Emphasize this especially if you have a larger,
high performance cabin cruiser where one normally moves
about during operation. Reduce speed considerably, or
stop completely if someone needs to move about the boat.
The driver should always use the safety kill switch! The kill
switch lanyard which is securely connected to the driver,
immediately shuts off the engine(s) should the driver be
thrown from the driving position. Even if the risk of being
thrown overboard is practically nonexistent in your type of
boat, the risk of the driver falling and being dazed in rough
seas can be even greater.
Remember, even when the engine(s) is stopped in a high
performance boat that is planing, it will travel approxi-
mately 325 feet (100 meters) before dropping through the
planing threshold and stopping!

7742836 07-2003 9
Introduction
Product and Application Information
Please complete this section for future reference.
Delivery date ___________________________________________________________________________
Engine model number ____________________________________________________________________
Engine serial number ____________________________________________________________________
Drive/Transmission model _________________________________________________________________
Drive/Transmission serial number ___________________________________________________________
Transom shield assembly serial number ______________________________________________________
Boat manufacturer ___________________________________ Boat year ___________________________
Boat model ________________________________________ Boat length _________________________
Hull ID number (HIN) _____________________________________________________________________
State/Province registration number __________________________________________________________
Propeller size __________________________________________________________________________
Selling dealer___________________________________________________________________________
Servicing dealer ________________________________________________________________________
It is very important that you obtain all serial numbers directly from serial number plates attached to product assemblies.
Check page 11 for the location of product serial number plates.
© 2002, Volvo Penta of the Americas, Inc. Volvo, Volvo Penta, DP Duoprop, and (Aquamatic) are ® of AB Volvo. DPX and QL are ® of AB Volvo Penta. DuraPlus, 2PLUS4, Speed Rails,
and Xact are trademarks of Volvo Penta of the Americas, Inc. SX Cobra and SX Diesel are trademarks of Volvo Penta Marine Products, L.P.
Volvo Penta reserves the right, without prior notice, to revise materials, standard equipment, specifications, models and to discontinue models. Not all models, equipment and accessories
are available in all markets or countries. Certain models and/or configurations may not be available at the time of publication. Representations made regarding these products
are subject to actual use, application, and/or operating conditions, as well as proper maintenance. The power rating data contained herein is for engines and conditions as tested
and may vary within manufacturing tolerances. Engines pictured in this brochure may feature custom accessories that are not necessarily standard on production models. Horsepower
ratings are in accordance with NMMA procedure.

10 7742836 07-2003
General Information
General Information
Identification numbers
Immediately upon taking delivery of your new boat, have
the dealer record the model and serial numbers of the
engine and drive in the Product and Application Informa-
tion space provided on page 9. (These numbers are
required for warranty registration, warranty service, and
ordering parts.) Include the model and serial number of
your boat and any auxiliary equipment. Also, make a copy
and keep the copy in a safe place in the event your boat is
stolen.
Owner’s identification card
When you purchased your boat, the dealer was required to
complete a warranty and registration form for your Volvo
Penta product. The owner’s portion of this form is your
Owner’s Identification Card. This card provides proof of
ownership and is required to validate warranty, should
warranty service be necessary. Warranty coverage may be
delayed until the warranty and registration form is on file at
Volvo Penta.
Product references, illustrations, and
specifications
All information, illustrations and specifications contained in
this manual are based on the latest product information
available at the time of printing. Volvo Penta of the Ameri-
cas, Inc. reserves the right to make changes at any time,
without notice, in specifications and models; to discontinue
models; to change any specifications or parts at any time
without incurring any obligation to equip same on models
manufactured prior to date of such change.
When reference is made in this manual to a brand name,
number, product or specific tool, an equivalent product
may be used in place of the product referred to unless
specifically stated otherwise. To avoid hazards, equivalent
products used must meet all current U.S. Coast Guard
Safety Regulations and American Boat and Yacht Council
(ABYC) standards.
All illustrations used in this manual may not depict actual
models or equipment and are intended as representative
views for reference only.
The continuing accuracy of this manual cannot be guaran-
teed.
Engine Tag

7742836 07-2003 11
General Information
Toll-free Dealer Locator Service
If you are away from your home waters, take
your Volvo Penta product to the nearest Volvo
Penta servicing dealer. To locate a Volvo Penta
servicing dealer, check the Yellow Pages under
Boat Dealers, or call 1-800-522-1959.
Volvo Action Service (VAS)
Volvo Action Service (VAS) is a consumer breakdown
service available 24 hours each day, 365 days per year. If
your engine breaks down, the VAS coordinator will quickly
locate your nearest dealer. If you need a tow, parts, or
mechanic, the VAS coordinator will make all arrangements
necessary to get you back underway as soon as possible.
Membership to Volvo Action Service is provided automati-
cally to all Volvo Penta engine owners. As long as your
Volvo Penta engine is under factory warranty, this service
is absolutely free for Volvo Penta-related repairs. Towing
is not covered by the Volvo Penta warranty. Once your
warranty period has expired, there is a charge of $50.00*
U.S. per managed breakdown, plus any additional costs
incurred for towing, parts, or repairs.
If you have a question about Volvo Action Service, or need
additional information, call toll-free 1-877-33-PENTA.
* Price subject to change without notice.
Doing your own maintenance and
repairs
If you plan to do your own maintenance and repairs on
your Volvo Penta products, you should purchase a set of
service manuals that pertain to your particular engine and
drive. Keep in mind, however, that there are certain tasks
that should only be performed by your Volvo Penta dealer.
He has the tools, expertise, and most current information
needed to properly perform these tasks.
“Dealer-only” maintenance items are listed in the
Mainte-
nance Schedule .
Parts and accessories
Genuine Volvo Penta parts are the result of many hours of
strenuous testing, and fulfill Volvo Penta’s strict quality and
safety requirements. Your authorized dealer has a com-
plete line of (or may order) genuine Volvo Penta parts,
accessories, coolants, and lubricants. When replacements
are required, use only Volvo Penta genuine parts.
Purchase all Volvo Penta replacement parts, accessories,
coolants, and lubricants from an authorized Volvo Penta
dealer. He has needed parts in stock for routine mainte-
nance, as well as the information needed to order special
parts and accessories for you.
Only authorized Volvo Penta dealers may purchase
genuine parts and accessories directly from the factory.
Volvo Penta does not sell to unauthorized dealers or retail
customers.

12 7742836 07-2003
General Information
Volvo Penta dealer network
Volvo Penta has a comprehensive dealer network that
offers both service and spare parts for Volvo Penta
engines. These dealers have been carefully selected and
trained to provide professional assistance for service and
repairs. They also have the special tools and testing
equipment required for maintaining a high standard of
service. Volvo Penta dealers and vendors must maintain a
stock of original spare parts and accessories to cover most
requirements of Volvo Penta owners. When ordering a
service or spare parts always quote the engine and drive/
reverse gear complete type designation and serial number.
You will find this information on the engine product plate
and on a decal on the valve cover.
Always take your Volvo Penta product to an authorized
Volvo Penta servicing dealer for repair. Our dealers have
the knowledge, factory-trained technicians, and special
tools to take care of any necessary repairs. Ideally, take
your product back to your selling dealer — he also knows
you and your equipment.
For the name and location of your nearest Volvo Penta
dealer, consult the Yellow Pages under Boat Dealers, or
call 1-800-522-1959.
Volvo Penta on the Internet
The URL address for Volvo Penta of the Americas is http:/
/www.volvopenta.com. When you reach the Volvo home
page, choose the Marine and Industrial Engines icon.

7742836 07-2003 13
General Information
Features
Your Volvo Penta product consists of two components: the engine and the drive. There are certain parts on each compo-
nent that you, the owner, must take care of to make sure that your Volvo Penta product stays in optimum running condi-
tion. The important parts of each component are shown in the Features pages. Explanations of these parts and systems
are described below; the maintenance procedures are found in the Maintenance section.
Fuse Box

14 7742836 07-2003
Features
1. Flame Arrestor (under cover)
2. Alternator
3. Engine Oil Filter
4. Oil Dipstick (engine)
5. Oil Withdrawal Tube
6. Serpentine Belt
7. Power Steering Fluid Fill Cap
8. Power Steering Pump
9. Raw Water Pump & Impeller
10. Fuel Pumps
11. Fuel Filter
12. Exhaust Hose
13. Engine Flush
14. Exhaust Clamps
15. Circuit Breaker/Fuses (under cover)
16. Exhaust Riser
17. Exhaust Manifold
12
4
5
6
7
9
8
10
11
13
15
23
4.3OSi-EF
Top View
18. Engine Drain
19. Drain (manifold)
20. Anodes (hidden)
21. Water Intake
22. Propellers & Shaft
23. Drive Oil Reservoir
24. Engine Coolant Fill
24

7742836 07-2003 15
Features
12
16
17
18
19
20
21
13
23
20
4.3OSi-EF
Starboard View
3
14
18
19
20
20
21
4.3OSi-EF
Port View
22
22

16 7742836 07-2003
Features
1. Flame Arrestor (under cover)
2. Alternator
3. Engine Oil Filter
4. Oil Dipstick (engine)
5. Oil Withdrawal Tube
6. Serpentine Belt
7. Power Steering Fluid Fill Cap
8. Power Steering Pump
9. Raw Water Pump & Impeller
10. Fuel Pumps
11. Fuel Filter
12. Exhaust Hose
13. Engine Flush
14. Exhaust Clamps
15. Circuit Breaker/Fuses (under cover)
16. Exhaust Riser
17. Exhaust Manifold
12
4
5
6
7
9
8
10
11
13
15
23
5.0OSi-EF, 5.7OSi-DF, 5.7OSXi-DF
Top View
18. Engine Drain
19. Drain (manifold)
20. Anodes (hidden)
21. Water Intake
22. Propellers & Shaft
23. Drive Oil Reservoir
24. Engine Coolant Fill
24

7742836 07-2003 17
Features
12
16
17
18
19
20
21
13
23
20
3
14
18
19
20
20
21
5.0OSi-EF, 5.7OSi-DF,
5.7OSXi-DF
Starboard View
5.0OSi-EF, 5.7OSi-DF,
5.7OSXi-DF
Port View
22
22

18 7742836 07-2003
Features
1. Flame Arrestor (under cover)
2. Alternator
3. Engine Oil Filter
4. Oil Dipstick (engine)
5. Oil Withdrawal Tube
6. Serpentine Belt
7. Power Steering Fluid Fill Cap
8. Power Steering Pump
9. Raw Water Pump & Impeller
10. Fuel Pumps
11. Fuel Filter
12. Exhaust Hose
13. Engine Flush
14. Exhaust Clamps
15. Circuit Breaker/Fuses (under cover)
16. Exhaust Riser
17. Exhaust Manifold
18. Engine Drain
19. Drain (manifold)
20. Anodes (hidden)
21. Water Intake
22. Propellers & Shaft
23. Drive Oil Reservoir
12
4
5
6
7
9
8
10
11
13
15
23
4.3OSi-E
Top View