Volvo penta 4.3osi-b User manual

OPERATOR’S MANUAL

4.3OSi-B,-BF

5.0OSi-B, -BF

5.7OSi-A, -AF, 5.7OSXi-A, -AF

7741783 © 12-2001 Printed in USA

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . 5

Our core values: Quality, Safety,

Environmental Care . . . . . . . . . . . . . . . . . . . . . . . 5

Factors that affect engine performance . . . . . . . . 5

Power ratings . . . . . . . . . . . . . . . . . . . . . . . . 5

How load conditions affect the speed

of a planing hull . . . . . . . . . . . . . . . . . . . . . . . 6

“Wagon-back” effect . . . . . . . . . . . . . . . . . . . 6

Your new boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Boater’s responsibilities . . . . . . . . . . . . . . . . . . . . 6

Planning your trip . . . . . . . . . . . . . . . . . . . . . 7

Safety equipment . . . . . . . . . . . . . . . . . . . . . 7

Basic safety rules of boating . . . . . . . . . . . . . 7

High performance boat operation . . . . . . . . . . . . . 7

Product and Application Information . . . . 9

General Information . . . . . . . . . . . . . . . . . 11

Identification numbers . . . . . . . . . . . . . . . . . . . . 11

Owner’s identification card . . . . . . . . . . . . . . 11

Product references, illustrations, and

specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Volvo Action Service (VAS) . . . . . . . . . . . . . . . . 12

Doing your own maintenance and repairs . . . . . . 12

Parts and accessories . . . . . . . . . . . . . . . . . . . . 12

Volvo Penta dealer network . . . . . . . . . . . . . . . . 13

Volvo Penta on the Internet . . . . . . . . . . . . . . . . 13

Warranty information . . . . . . . . . . . . . . . . . . . . . 13

2 PLUS 4™ Extended Protection . . . . . . . . . . . . 13

Features . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Circuit breakers and fuses . . . . . . . . . . . . . . . . . 15

4.3 OSi Engine, front View . . . . . . . . . . . . . . . . . 16

4.3 OSi Engine, starboard view . . . . . . . . . . . . . 17

4.3 OSi Engine, port view . . . . . . . . . . . . . . . . . . 17

5.0 OSi, 5.7 OSi/OSXi Engine, front View . . . . . 18

5.0 OSi, 5.7 OSi/OSXi Engine, starboard view . . 19

5.0 OSi, 5.7 OSi/OSXi Engine, port view . . . . . . 19

4.3 OSi Engine, front View . . . . . . . . . . . . . . . . . 20

4.3 OSi Engine, starboard view . . . . . . . . . . . . . 21

4.3 OSi Engine, port view . . . . . . . . . . . . . . . . . . 21

5.0 OSi, 5.7 OSi/OSXi Engine, front View . . . . . 22

5.0 OSi, 5.7 OSi/OSXi Engine, starboard view . . 23

5.0 OSi, 5.7 OSi/OSXi Engine, port view . . . . . . 23

Anodes (“sacrificial”) . . . . . . . . . . . . . . . . . . . . . 24

Audible alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Contents

Engine systems . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cooling system . . . . . . . . . . . . . . . . . . . . . . 24

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . 24

Exhaust system . . . . . . . . . . . . . . . . . . . . . 24

Electrical system . . . . . . . . . . . . . . . . . . . . 24

Electronic Fuel Injection (EFI) . . . . . . . . . . . 24

Lubrication system . . . . . . . . . . . . . . . . . . . 25

Steering system . . . . . . . . . . . . . . . . . . . . . 25

Drive components . . . . . . . . . . . . . . . . . . . . . . . 25

Emergency stop switch . . . . . . . . . . . . . . . . . . . 25

Engine protection mode (EFI systems) . . . . . . . 25

Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Engine instruments . . . . . . . . . . . . . . . . . . . 26

Trim instruments . . . . . . . . . . . . . . . . . . . . . 26

Trim/tilt motor protection . . . . . . . . . . . . . . . 26

Impact protection . . . . . . . . . . . . . . . . . . . . 27

Power trim/tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

XDP sterndrive propeller choice . . . . . . . . . . 29

Twin engine installation . . . . . . . . . . . . . . . . 29

Remote controls . . . . . . . . . . . . . . . . . . . . . . . . 30

Trim controls . . . . . . . . . . . . . . . . . . . . . . . . 31

Operating trim controls . . . . . . . . . . . . . . . . 31

Operation . . . . . . . . . . . . . . . . . . . . . . . . . 33

Engine break-in period . . . . . . . . . . . . . . . . . . . . 33

First service inspection . . . . . . . . . . . . . . . . . . . 34

Operating after break-in period . . . . . . . . . . . . . . 34

Starting the engine (cold start) . . . . . . . . . . . . . . 35

Starting the engine (warm start) . . . . . . . . . . . . . 35

Stopping the engine . . . . . . . . . . . . . . . . . . . . . . 35

Operating remote controls . . . . . . . . . . . . . . . . . 35

Side mount control . . . . . . . . . . . . . . . . . . . 35

Top mount control . . . . . . . . . . . . . . . . . . . . 36

Steering system operation . . . . . . . . . . . . . . . . . 36

Twin unit steering . . . . . . . . . . . . . . . . . . . . 36

Power trim and tilt operation . . . . . . . . . . . . . . . 36

Power trim operation . . . . . . . . . . . . . . . . . . 36

Determining the proper trim . . . . . . . . . . . . . 36

Operating in “bow-up” position . . . . . . . . . . . 36

Operating in “bow-down” position . . . . . . . . . 37

Power tilt operation . . . . . . . . . . . . . . . . . . . 37

Power trim/tilt switch operation . . . . . . . . . . 37

Power trim/tilt switch and gauge location . . . 38

Shifting and controlling speed . . . . . . . . . . . . . . 38

Checking instruments . . . . . . . . . . . . . . . . . . . . 38

2

Special boating circumstances . . . . . . . . . . . . . 39

Engine protection mode operation

(fuel injection systems) . . . . . . . . . . . . . . . . 39

Shallow water operation . . . . . . . . . . . . . . . . 39

High altitude operation . . . . . . . . . . . . . . . . . 39

Operating procedure for freezing

temperatures . . . . . . . . . . . . . . . . . . . . . . . . 39

Salt water operation . . . . . . . . . . . . . . . . . . 39

Twin unit operation . . . . . . . . . . . . . . . . . . . . 39

Trailering your boat . . . . . . . . . . . . . . . . . . . . . . 39

Propeller selection . . . . . . . . . . . . . . . . . . . . . . . 40

Maintenance . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance schedule . . . . . . . . . . . . . . . . . . . . 41

Preparing for boating after storage (launching) . . 43

Off-season storage preparations (“winterization”) 43

Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . 43

Engine exhaust system . . . . . . . . . . . . . . . . 43

Drive unit bellows . . . . . . . . . . . . . . . . . . . . 43

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Gasoline recommendations . . . . . . . . . . . . . . .

Gasoline containing alcohol . . . . . . . . . . . . . 44

Detonation (spark knock) . . . . . . . . . . . . . . 44

Preventing gum formation and

corrosion in the fuel system . . . . . . . . . . . . 44

Electronic fuel injection . . . . . . . . . . . . . . . . 45

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

Multiple batteries and selector switch . . . . . 47

Distributor cap and rotor . . . . . . . . . . . . . . . 48

Circuit breakers and fuses . . . . . . . . . . . . . . 49

Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . 49

Checking and changing spark plugs . . . . . . 49

Belt adjustments . . . . . . . . . . . . . . . . . . . . . 49

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 50

Draining the cooling system . . . . . . . . . . . . 50

Engine — fresh water cooled . . . . . . . . . . . . 50

Engine — raw water cooled . . . . . . . . . . . . . 50

Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Steering system . . . . . . . . . . . . . . . . . . . . . . . . . 51

Power trim/tilt fluid level . . . . . . . . . . . . . . . . 51

Steering reservoir fluid level . . . . . . . . . . . . . 51

Primary shaft spline and bearing lubrication . 51

Engine and drive service . . . . . . . . . . . . . . . . . . 51

Lubrication system . . . . . . . . . . . . . . . . . . . . . . 52

Engine/crankcase oil . . . . . . . . . . . . . . . . . . 52

Checking engine oil level . . . . . . . . . . . . . . . 52

Changing engine oil . . . . . . . . . . . . . . . . . . . 52

Changing the oil filter . . . . . . . . . . . . . . . . . . 52

Drive components . . . . . . . . . . . . . . . . . . . . . . . 53

External lubrication points . . . . . . . . . . . . . . 53

External lubrication points . . . . . . . . . . . . . . 54

Anodes (“sacrificial” anodes) . . . . . . . . . . . . 54

Active corrosion protection system . . . . . . . 55

Neutra-Salt system . . . . . . . . . . . . . . . . . . . 55

Propeller care . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Propeller replacement — XDP . . . . . . . . . . . 56

Boat bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Engine alignment . . . . . . . . . . . . . . . . . . . . . . . . 57

Replacement parts . . . . . . . . . . . . . . . . . . . . . . . 57

Bottom painting . . . . . . . . . . . . . . . . . . . . . . . . . 57

Engine submersion . . . . . . . . . . . . . . . . . . . . . . 57

Troubleshooting . . . . . . . . . . . . . . . . . . . 59

Problem Resolution . . . . . . . . . . . . . . . . 61

Warranty Information . . . . . . . . . . . . . . . . 63

Specifications . . . . . . . . . . . . . . . . . . . . . 65

4.3 OSi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.0 OSi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.7 OSi/OSXi . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Appendix A: Certified Engines . . . . . . . . 69

Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 69

Bodensee Shiffahrts Ordnung (BSO) number . . . 69

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3

Safety

This owner’s manual contains information you need to op-

erate 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 infor-

mation concerning the engine and drive: model identifica-

tion, 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 infor-

mation provided in the manual gives the owner

important information about maintaining the engine

and drive.

If you do not understand or are uncertain about any opera-

tion 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

owners in the event that a safety related defect is

discovered on any of their products. If you are not the

original owner of this engine and drive, please notify

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.

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 dan-

gers, warnings, and cautions. They warn you of possible

dangers or important information contained in this manual.

HOWEVER: Warnings alone do not eliminate haz-

ards, 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 occu-

pants, and/or others.

WARNING!

Failure to comply with a warning may result 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.

Below is a summary of the risks and safety precautions you

should always observe or carry out when operating or servic-

ing the engine:

1. Check that the warning or information decals on the

engine are always clearly visible. Replace decals that

have been damaged or painted over.

2. Always turn the engine off before starting service pro-

cedures. 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 start-

ing 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

operations before starting the engine. Make a point of

familiarizing yourself with other risk factors, such as

rotating parts and hot surfaces (exhaust manifold,

starter, etc.).

5. Approaching a running engine is dangerous. Loose

clothing 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 be-

fore 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

system pressure gradually; otherwise, steam or hot

coolant can spray out.

9. Stop the engine and close or block the sea water in-

take before carrying out operations on the engine cool-

ing system.

10. Only start the engine in a well-ventilated area. If oper-

ating 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.

4

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 packaging. 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; oth-

erwise, 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

batteries. The batteries give off hydrogen gas during

charging which when mixed with air can form an explo-

sive 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 battery connections when starting the en-

gine (spark risk) and do not lean over batteries.

15. Always ensure that the positive and negative battery

leads are correctly installed on the corresponding ter-

minal posts. Incorrect installation can result in serious

damage to electrical equipment.

16. Always use protective goggles when charging and

handling batteries. Battery electrolyte contains sulfu-

ric 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 medi-

cal assistance.

17. To ensure safe handling and to avoid damaging

5

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 ma-

rine engine industry. From engineering design and manufac-

turing to support activities in Parts, Service, and Sales, high

standards have been set to ensure your pride and satisfac-

tion 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 ser-

vice 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, En-

vironmental 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 development of all

of our products, processes, and services. It is on these val-

ues and qualities that the Volvo Penta corporate 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 ultimately help us to survive.

Quality

is a value that traditionally referred to product quality

but now encompasses all aspects of our products and ser-

vices. In today’s competitive environment, Volvo Penta’s qual-

ity 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 environ-

mental values.

Environmental care

in all operations, from design to produc-

tion, distribution, service, and recycling, is an integral part of

the Volvo quality commitment towards customers, employ-

ees, and the community. By embracing the environment as a

core value, Volvo demonstrates its understanding of the envi-

ronmental impact its products have upon nature and the shared

urban and rural surroundings.

Volvo Penta continually commits a considerable part of its

development resources toward minimizing the environmen-

tal impact of its products. Examples of areas where we are

always looking for improvements are exhaust emissions, noise

levels, and fuel consumption.

Introduction

Regardless of whether your Volvo Penta engine is installed in a

boat used for pleasure or commercial operation, incorrect op-

eration or improper maintenance of the engine will result in

disturbance or damage to the environment.

In this owner’s manual there are a number of service proce-

dures, 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 en-

gine 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.

Factors that affect engine perfor-

mance

Power ratings

A great number of environmental factors, such as barometric

pressure, ambient temperature, humidity, the quality of fuel,

and exhaust back pressure can affect engine performance.

When it comes to quoting and comparing ratings, it is impor-

tant that there is a unified set of standards for measurement.

In September 1989, all major marine engine manufacturers

agreed to quote engine power output according to a com-

mon set of conditions. These conditions are referred to as

ISO 8665.

All Volvo Penta engines meet the ISO 8665 stan-

dard. This ISO standard outlines the following fixed values or

common conditions for determining the rating of the engine.

Condition Value

Sea water temperature 77°F (25°C)

Fuel Temperature 104°F (40°C)

Air Temperature 77°F (25°C)

Condition

Exhaust back-pressure 1.45 PSI (10 kPa)

Barometric pressure 14.504 PSI (100 kPa)

Relative humidity 30%

Value

6

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 combustion.

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 plan-

ing 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 over-

all weight encountered in normal cruising, particularly in

hotter climates. Although this will reduce top speed some-

what, 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 in-

fluence on boat performance is marine growth beneath the

waterline - a problem that is often overlooked.

“Wagon-back” effect

As long as we continue to use combustion technology for

engines, there will be exhaust emissions. Despite the sub-

stantial reductions achieved in modern engines, as fuel 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

“wagon-back 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 cre-

ates its own wagon-back effect. This recirculating air has a

tendency to draw exhaust fumes and water spray up to-

ward 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 concentra-

tions these fumes may be hazardous. If you suspect that

your boat exhibits this “wagon-back” effect, please contact

your Volvo Penta dealer.

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 infor-

mation on operation and maintenance. Please read it care-

fully, 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

Maintenance Sched-

ule

) The owner must keep records of all maintenance ser-

vices performed. This record of proper maintenance may

be required to determine warranty coverage on certain re-

pairs and should be transferred to each subsequent owner.

If you are not sure of the proper maintenance procedures,

contact the Volvo Penta Consumer 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 equipment 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 main-

tenance of the boat.

7

• 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 flota-

tion devices and signal rockets. Make sure all pas-

sengers 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 propel-

ler 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 in-

tended for use as seats.

• Insist on the use of personal flotation devices by all

passengers 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 information about boating safety at

WWW.USCGBOATING.ORG and

WWW.CGAUX.ORG/CGAUXWEB/PUBLIC/

PUBFRAME.HTM.

• Prevent explosion and fire by maintaining your fuel

delivery system in top condition. Fuel vapor is vola-

tile; handle fuel with care.

• Keep your boat and equipment neat and in top oper-

ating 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.

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 ad-

visable 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 boat-

ers 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 pos-

sible hazards! Always allow for adequate reaction time. Al-

ways reduce speed when visibility is reduced for whatever

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 com-

pletely 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 approximately

325 feet (100 meters) before dropping through the planing

threshold and stopping!

8

........................................................................................................................................................

Notes

9

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.

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.

Product and Application Information

10

........................................................................................................................................................

Notes

11

Identification numbers

Immediately upon taking delivery of your new boat, have

the dealer record the model and serial numbers of the en-

gine and drive in the

Product and Application Information

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 own-

ership 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 specifi-

cally stated otherwise. To avoid hazards, equivalent prod-

ucts 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 model number

Transom shield model number

Drive unit model number

General Information

12

Volvo Action Service (VAS)

Volvo Action Service (VAS) is a consumer breakdown ser-

vice available 24 hours each day, 365 days per year. If your

engine breaks down, the VAS coordinator will quickly lo-

cate your nearest dealer. If you need a tow, parts, or me-

chanic, 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 war-

ranty 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, ac-

cessories, 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 genu-

ine parts and accessories directly from the factory. Volvo

Penta does not sell to unauthorized dealers or retail cus-

tomers.

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.

13

Volvo Penta dealer network

Volvo Penta has a comprehensive dealer network that of-

fers 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 deal-

ers 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 al-

ways 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.penta.volvo.se. When you reach the Volvo

home page, choose the

Marine and Industrial Engines

icon.

14

........................................................................................................................................................

Notes

15

Your Volvo Penta product consists of two components: the engine and the drive. 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

Features

pages. Explanations of these parts and systems are de-

scribed below; the maintenance procedures are found in the

Maintenance

section.

Features

Circuit breakers and fuses

All OSi/OSXi Series Engines

16

4.3 OSi with fresh water cooling (front view)

Item Description

1

Item Description

14

Expansion Tank

Flame Arrestor (under cover)

Serpentine Belt

Oil Dipstick (engine)

Oil Withdrawal Tube

Engine Oil Filter

Alternator

Exhaust Hose

Heat Exchanger

Power Steering Pump

Raw Water Pump & Impeller

Power Steering Fluid Fill Cap Drain(manifold)

Exhaust Manifold

Engine Drain

Circuit Breaker/Fuses (under cover)

Exhaust Riser

Exhaust Clamps

Audible Alarm

Propellers & Shaft

Water Intake

Anode

3

10

11

9

8

5

6

4

12

22

17

20

23

25

24

16

21

15

19

13

Fuel Pumps Spark Plugs & Wires

Fuel Filter

2

26 Drive Oil Reservoir

7

18

1

2

3

4

7

8

9

10

11

12

13

22

20

17

4.3 OSi (starboard view)

4.3 OSi (port view)

4

5

6

14

15

17

19

21

11

13

14

16

18

22

24

23

25

26

18

5.0 OSi and 5.7 OSi/OSXi with fresh water cooling (front view)

Item Description

1

Item Description

14

Expansion Tank

Flame Arrestor (under cover)

Serpentine Belt

Oil Dipstick (engine)

Oil Withdrawal Tube

Engine Oil Filter

Alternator

Exhaust Hose

Heat Exchanger

Power Steering Pump

Raw Water Pump & Impeller

Power Steering Fluid Fill Cap Drain(manifold)

Exhaust Manifold

Engine Drain

Circuit Breaker/Fuses (under cover)

Exhaust Riser

Exhaust Clamps

Audible Alarm

Propellers & Shaft

Water Intake

Anode

3

10

11

9

7

8

5

6

4

12

18

22

17

20

23

25

24

16

21

15

19

13

Fuel Pumps Spark Plugs & Wires

Fuel Filter

2

26 Drive Oil Reservoir

1

2

3

4

7

8

9

10

11

12

13

22

20

Volvo Penta 4.3OSi-B User manual

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