Volvo Penta 4.3OSi-C User manual

OPERATORS MANUAL
4.3OSi-C, 4.3OSi-CF
5.0OSi-C, 5.0OSi-CF
5.7OSi-B, 5.7OSi-BF
5.7OSXi-B, 5.7OSXi-BF

1
Introduction
Our core values: Quality, Safety, Environmental Care ............................................... 7
Factors that affect engine performance ....................................................................... 8
Power ratings ................................................................................................................. 8
How load conditions affect the speed of a planing hull ............................................. 8
“Wagon-back” effect...................................................................................................... 8
Your new boat ................................................................................................................ 9
Boater’s responsibilities ............................................................................................... 9
Planning your trip .......................................................................................................... 9
Safety equipment ........................................................................................................... 9
Basic safety rules of boating ........................................................................................ 9
High performance boat operation .............................................................................. 10
Product and Application Information ......................................................................... 11
General Information ..................................................................................... 12
Identification numbers................................................................................................. 12
Owner’s identification card ......................................................................................... 12
Product references, illustrations, and specifications ............................................... 12
Volvo Action Service (VAS) ......................................................................................... 13
Doing your own maintenance and repairs ................................................................. 13
Parts and accessories ................................................................................................. 13
Volvo Penta dealer network ........................................................................................ 14
Volvo Penta on the Internet......................................................................................... 14
Features ........................................................................................................ 15
4.3OSi-CF ...................................................................................................................... 16
5.0OSi-CF, 5.7OSi-BF, 5.7OSXi-BF ............................................................................. 18
4.3OSi-C ........................................................................................................................20
5.0OSi-C, 5.7OSi-B, 5.7OSXi-B .................................................................................... 22
Anodes (“sacrificial”) .................................................................................................. 24
Audible alarm (optional) .............................................................................................. 24
Operation ...................................................................................................... 24
Engine systems ............................................................................................................ 24
Cooling system ............................................................................................................ 24
Fuel system .................................................................................................................. 24
Exhaust system ............................................................................................................ 24
Electrical system.......................................................................................................... 24
Electronic Fuel Injection (EFI)..................................................................................... 25
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
Analog trim instrument................................................................................................ 26
Digital trim instrument (optional)................................................................................ 26

2
Trim/tilt motor protection ............................................................................................ 27
Impact protection ......................................................................................................... 27
If you strike a solid object: .......................................................................................... 28
Power trim/tilt ............................................................................................................... 28
Propellers ...................................................................................................... 29
Propeller Selection ...................................................................................................... 29
“D” series aluminum propellers ................................................................................................................. 29
“F” series stainless steel propellers .......................................................................................................... 29
“X” series composite propellers ................................................................................................................ 29
Twin engine installation .............................................................................................. 30
XDP drive unit .............................................................................................................. 30
Remote controls ........................................................................................... 31
Trim controls ................................................................................................................ 31
Operating trim controls ............................................................................................... 31
Control panel ................................................................................................................ 31
Control lever ................................................................................................................. 32
Control lever with catch button (single installation) ................................................. 32
Control lever with catch button (twin installation) .................................................... 32
Engine break-in period ................................................................................................ 33
First two hours ............................................................................................................. 34
Next eight hours ........................................................................................................... 34
Final ten hours ............................................................................................................. 34
First service inspection (Dealer 20-hour check) ....................................................... 34
Start the engine and check that .................................................................................. 34
Stop the engine and ..................................................................................................... 34
Restart the engine and recheck that .......................................................................... 34
Operating after break-in period .................................................................................. 35
Starting the engine, cold start .................................................................................... 35
If the engine floods: ..................................................................................................... 35
Starting the engine (warm start) ................................................................................. 35
If the engine floods: ..................................................................................................... 35
Stopping the engine..................................................................................................... 36
Operating remote controls .......................................................................................... 36
Side mount control ...................................................................................................... 36
Top mount control ....................................................................................................... 36
Steering system operation .......................................................................................... 36
Twin unit steering ........................................................................................................ 36
Power trim and tilt operation ...................................................................................... 37
Power trim operation ................................................................................................... 37
Determining the proper trim ........................................................................................ 37
Operating in “bow-up” position .................................................................................. 37
Operating in “bow-down” position ............................................................................. 37
Power tilt operation...................................................................................................... 38
Power trim/tilt switch operation.................................................................................. 38
Power trim/tilt switch and gauge location ................................................................. 39
Shifting and controlling speed ................................................................................... 39
Checking instruments ................................................................................................. 40

3
Special boating circumstances................................................................... 41
Engine protection mode operation ............................................................................. 41
Shallow water operation .............................................................................................. 41
High altitude operation ................................................................................................ 41
Operating procedure for freezing temperatures ....................................................... 41
Salt water operation ..................................................................................................... 41
Twin engine operation ................................................................................................. 41
Trailering your boat ..................................................................................................... 42
Propeller selection ....................................................................................................... 42
Maintenance schedule ................................................................................. 43
Preparing for boating after storage (launching) ........................................................ 45
Off-season storage preparations (“winterization”) ................................................... 45
Exhaust system ............................................................................................................ 45
Engine exhaust system ............................................................................................... 45
Drive unit bellows ........................................................................................................ 45
Fuel system .................................................................................................................. 46
Gasoline recommendations ........................................................................................ 46
Gasoline containing alcohol ....................................................................................... 46
Detonation (spark knock) ............................................................................................ 46
Preventing gum formation and corrosion in the fuel system .................................. 46
Electronic fuel injection............................................................................................... 46
Flame arrestor .............................................................................................................. 47
Electric fuel pumps ...................................................................................................... 47
Fuel filter ....................................................................................................................... 47
Engine fuel filter replacement ..................................................................................... 47
Electrical system.......................................................................................................... 48
Battery cables .............................................................................................................. 48
Batteries and connections .......................................................................................... 48
Spark Plug Tables ........................................................................................................ 50
Distributor cap and rotor ............................................................................................. 50
Circuit breakers and fuses .......................................................................................... 50
Spark plugs .................................................................................................................. 50
Checking and changing spark plugs ......................................................................... 51
Belt adjustments .......................................................................................................... 53
Cooling system ............................................................................................................ 54
Engine overheating ...................................................................................................... 54
Draining the cooling system ....................................................................................... 55
Engine Flush ................................................................................................................ 55
Raw Water Cooled........................................................................................................ 56
Closed Cooling System ............................................................................................... 57
Power trim/tilt fluid level.............................................................................................. 58
Steering system ........................................................................................................... 58
Steering reservoir fluid level ....................................................................................... 58
Primary shaft spline lubrication ................................................................................. 58
Engine and drive service ............................................................................................. 58
Engine/crankcase oil ................................................................................................... 59
Checking engine oil level ............................................................................................ 59

4
Changing engine oil ..................................................................................................... 60
Changing the oil filter .................................................................................................. 60
Drive Components ....................................................................................................... 60
External lubrication points .......................................................................................... 60
Lubricating the drive unit (XDP) ................................................................................. 60
Adding lubricant........................................................................................................... 60
Anodes (“sacrificial” anodes) ..................................................................................... 61
Neutra-Salt System ...................................................................................... 62
System Operation ........................................................................................................ 62
Propeller care ............................................................................................... 64
Propeller Installation.................................................................................................... 65
D or F-Series ............................................................................................................................................ 65
X-Series ................................................................................................................................................... 66
Replacement parts ....................................................................................................... 67
Boat bottom .................................................................................................................. 67
Bottom painting............................................................................................................ 67
Engine alignment ......................................................................................................... 67
Engine submersion ...................................................................................................... 67
Troubleshooting ........................................................................................... 68
Problem Resolution ..................................................................................................... 69
Warranty information ................................................................................................... 69
Warranty Registration Form ........................................................................................ 69
Certified engines .......................................................................................................... 70
Bodensee Shiffahrts Ordnung (BSO) number ............................................................... 70
Specifications
4.3 OSi ........................................................................................................................... 71
Oil capacity ............................................................................................................................................... 71
Oil type ..................................................................................................................................................... 71
5.0 OSi ........................................................................................................................... 72
Oil capacity ............................................................................................................................................... 72
Oil type ..................................................................................................................................................... 72
5.7 OSi/OSXi ................................................................................................................. 73
Oil capacity ............................................................................................................................................... 73
Oil type ..................................................................................................................................................... 73

5
This owner’s manual contains information you need to oper-
ate 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 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 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 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 dan-
gers, 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 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.

6
Below is a summary of the risks and safety precautions you
should always observe or carry out when operating or ser-
vicing 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

7
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 manu-
facturing to support activities in Parts, Service, and Sales,
high standards have been set to ensure your pride and sat-
isfaction 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, ser-
vice 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 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 be-
lieve in as a company and will ultimately help us to survive.
Quality is a value that traditionally referred to product qual-
ity 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 environ-
mental values.
Environmental care in all operations, from design to pro-
duction, 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
environmental 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.
Regardless of whether your Volvo Penta engine is installed
in a boat used for pleasure or commercial operation, incor-
rect operation 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 wild-
life, 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.

8
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 mea-
surement.
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 en-
gine.
Condition .................................................................... Value
Sea Water ........................................................ 77°F (25°C)
Fuel Temperature .......................................... 104°F (40°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 combustion.
Marine engines can be rated according to one of several
power standards, but power output itself is quoted in kilo-
watts (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-plan-
ing 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 re-
duce 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 en-
hanced acceleration.
In considering the influence of weight, it is worth remember-
ing that fiberglass boats absorb a significant amount of wa-
ter 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 water-
line - 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 fre-
quently 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
wagon-back 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 ven-
tilator or port hole in order to remove the fumes, but it has
the opposite effect — more fumes are drawn in, and condi-
tions merely become worse. In high concentrations these
fumes may be hazardous. If you suspect that your boat ex-
hibits this “wagon-back” effect, please contact your Volvo
Penta dealer.

9
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
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 repairs
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 mainte-
nance 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.

10
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 sur-
rounding 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 driv-
ing 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 whatever rea-
son.
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!

11
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.

12
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 Information space
provided on page 9. (These numbers are required for war-
ranty registration, warranty service, and ordering parts.) In-
clude 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 avail-
able at the time of printing. Volvo Penta of the Americas, Inc.
reserves the right to make changes at any time, without no-
tice, in specifications and models; to discontinue models; to
change any specifications or parts at any time without incur-
ring 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 Tag

13
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 ser-
vice 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 automatically 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 prop-
erly 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 complete
line of (or may order) genuine Volvo Penta parts, accesso-
ries, coolants, and lubricants. When replacements are re-
quired, 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 maintenance,
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 custom-
ers.

14
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 always quote
the engine and drive/reverse gear complete type designa-
tion 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 knowl-
edge, 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 equip-
ment.
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.

15
Features
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.

16
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-CF
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

17
12
16
17
18
19
20
21
13
23
20
4.3OSi-CF
Starboard View
3
14
18
19
20
20
21
4.3OSi-CF
Port View
22
22

18
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-CF, 5.7OSi-BF, 5.7OSXi-BF
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