Volvo penta 5.0 gl User manual

Workshop Manual

Engine

2(0)

5.0 GL

5.7 Gi

5.0/5.7 GXi

5.0/5.7 OSi, 5.7 OSXi

copied, photocopied, reproduced, or converted to any electronic or machine-readable form in whole

or in part without the express written consent from Volvo Penta of the Americas, Inc.

VPA 7748089 English 09-2007 i

Model Identification . . . . . . . . . . . . . . . . . . 1

General Information . . . . . . . . . . . . . . . . . . 3

Engine — 5.0 & 5.7 Litre . . . . . . . . . . . . . 29

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1

ii VPA 7748089 English 09-2007

Notes

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

VPA 7748089 English 09-2007 1

Model Identification

This workshop manual applies to the products listed in Service Bulletin 04-2-67 version 1 dated 08-2007. The unit

that you are servicing may be identified from the product model identification plates and/or decals that are placed

in various locations to identify Volvo Penta engines, transmissions, transom shields, and drives.

All sterndrive system components must be matched for either single or dual engine installations. Failure to properly

match engine, transmission, transom shield, and drive unit will result in poor boat performance, and risk damage

to engine and drive because of incorrect drive gear ratio.

On 3.0L engines, the model identification plate is lo-

cated on the side of the valve cover.

4.3, 5.0, and 5.7 Gi, GXi, OSi, OSXi models

8.1 Gi, GXi, OSi models

All GL models

For all other engines, the model identification plate or

decal is located either on the port side of the engine

cover and/or next to the flywheel housing.

23737-1

PROD.

NO.

SER. NO.

TYPE

TRANSOM ASSEMBLY

REVERSE GEAR

DRIVE UNIT

ENGINE

XXXXXXXXXX (B)

XXXXXXXXXX (A)

XXX XXX (C)

TRANSOM ASSEMBLY

REVERSE GEAR

DRIVE UNIT

ENGINE

XXXXXXXXXX (B)

XXXXXXXXXX (A)

XXX XXX (C)

TRANSOM ASSEMBLY

REVERSE GEAR

DRIVE UNIT

ENGINE

XXXXXXXXXX (B)

XXXXXXXXXX (A)

XXX XXX (C)

Model Identification

2VPA 7748089 English 09-2007

The XP transom shield identification plate is located

on the inner transom plate, above the steering ram.

The XDP sterndrive model identification plate is locat-

ed on top of the drive, in front of the upper gear hous-

ing cover.

The SX-A transom identification plate is located on the

lower left of the outer transom plate.

The identification plate for the SX-A/DPS-A stern-

drives is located on the rear of the upper gear, just

above the parting line between the upper and lower

gear housing.

50328

PROD.

NO.

TYPE

SER. NO.

POD

NO.

SR.

50327

50478

50315

VPA 7748089 English 09-2007 3

General Information

Tuning the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Intake Manifold Vacuum Testing . . . . . . . . . . . . . . . . . . . . . . . . 7

Gasoline Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gasoline Containing Alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Power Trim/Tilt Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Off-Season Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Preparation for Boating After Storage . . . . . . . . . . . . . . . . . . 15

Engine Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Submerged Engine or Water Ingestion in Cylinders . . . . . . . 18

20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Positive Closed Ventilation System . . . . . . . . . . . . . . . . . . . . 19

Troubleshooting - System Isolation . . . . . . . . . . . . . . . . . . . . 20

Engine Troubleshooting Guides . . . . . . . . . . . . . . . . . . . . . . . 21

This service manual is divided into sections concerning various sys-

tems and assemblies. Refer to the Contents to locate the section

covering the system or assembly requiring service. Each section title

page has an additional listing that will describe the sections contents

in more detail. Be sure to read the Safety Section at the end of this

manual, and pay special attention to all safety warnings as they ap-

pear throughout the text. Since models are subject to change at any

time, some photos may not depict actual product.

Good Service Practice

Service required for stern drives is generally one of three kinds:

•Normal care and maintenance - which includes putting a

new stern drive into operation, storing engines, lubrication,

and care under special operating conditions such as salt

water and cold weather.

•Operating malfunctions - due to improper engine or drive

mounting, propeller condition or size, boat condition, or the

malfunction of some part of the engine. This includes engine

servicing procedures to keep the engine in prime operating

condition.

•Complete disassembly and overhaul - such as major ser-

vice or rebuilding a unit.

It is important to determine before disassembly just what the trouble

is and how to correct it quickly, with minimum expense to the owner.

When repairing an assembly, the most reliable way to ensure a good

job is to do a complete overhaul on that assembly, rather than just to

replace the bad part. Wear not readily apparent on other parts could

cause malfunction soon after the repair job. Repair kits and seal kits

General Information

4VPA 7748089 English 09-2007

contain all the parts needed to ensure a complete repair, to eliminate

guesswork, and to save time.

Repair time can also be minimized by the use of special tools. Volvo

Penta special tools are designed to perform service procedures

unique to the product that cannot be completed using tools from oth-

er sources. They also speed repair work to help achieve service flat

rate times. In some cases, the use of substitute tools can damage

the part.

Preparation for Service

Proper preparation is extremely helpful for efficient service work. A

clean work area at the start of each job will minimize tools and parts

becoming misplaced. Clean an engine that is excessively dirty be-

fore work starts. Cleaning will occasionally uncover trouble sources.

Obtain tools, instruments and parts needed for the job before work

is started. Interrupting a job to locate special tools or repair kits is a

needless delay.

CAUTION!

Use proper lifting and handling equipment. Working on

engines or stern drives without proper equipment can

cause damage and personal injury.

Always use clean fresh fuel when testing engines. Troubles can of-

ten be traced to the use of old or dirty fuel.

Service Policy

It is a Volvo Penta policy to provide dealers with service knowledge

so they can give professional service demanded by today’s consum-

er. The Volvo Penta Training Centers, frequent mailing of Service

Bulletins, Letters and Promotions, Special Tools and this Service

Manual represent the latest effort to assist dealers in giving consum-

ers the best and most prompt service possible. If a service question

does not appear to be answered in this manual, you are invited to

write to the Volvo Penta Service Department for additional help. Al-

ways be sure to give complete information, including engine model

number and serial number.

Replacement Parts

WARNING!

When replacement parts are required, always use genu-

ine Volvo Penta parts, or parts with equivalent charac-

teristics, including type, strength, and material. Failure

to do so may result in product damage and possible

injury to the operator and/or passengers.

Parts Catalogs

Parts Catalogs contain exploded views showing the correct assem-

bly of all parts, as well as a complete listing of the parts for replace-

ment. These catalogs are helpful as a reference during disassembly

and reassembly, and are available from Volvo Penta Parts.

VPA 7748089 English 09-2007 5

General Information

Special Service Tools

Volvo Penta has specially designed tools to simplify some of the dis-

assembly and assembly operations. These tools are illustrated in

this Service Manual, in many cases in actual use. All special tools

can be ordered from Volvo Penta Parts. Individual purchasers of

Service Manuals must order Special Tools through an authorized

dealer.

Product References, Illustrations & Specifications

Volvo Penta reserves the right to make changes at anytime, without

notice, in specifications and models and also to discontinue models.

The right is also reserved 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. All information, illustra-

tions and specifications contained in this manual are based on the

latest product information available at the time of printing. The right

is reserved to make changes at anytime without notice.

All photographs and illustrations used in this manual may not depict

actual models or equipment, but are intended as representative

views for reference only. The continuing accuracy of this manual

cannot be guaranteed.

The purpose of an engine tune-up is to restore power and perfor-

mance that has been lost through wear, corrosion or deterioration of

one or more parts or components. In the normal operation of an en-

gine, these changes can take place gradually at a number of points,

so that it is seldom advisable to attempt an improvement in perfor-

mance by correction of one or two items only. Time will be saved and

more lasting results will be obtained by following a definite and thor-

ough procedure of analysis and correction of all items affecting pow-

er and performance.

Economical, trouble-free operation can better be ensured if a com-

plete tune-up is performed once every year, preferably in the spring.

Components that affect power and performance can be divided into

three groups:

• Components affecting compression

• Components affecting ignition

• Components affecting fuel system

Tuning the Engine

Tune-up procedures should cover these groups in the order given.

While the items affecting compression and ignition may be handled

according to personal preference, correction of items in the fuel sys-

tem group should not be attempted until all items affecting compres-

sion and ignition have been satisfactorily corrected. Most of the

procedures for performing a complete engine tune-up will be cov-

ered in greater detail in this manual. This section will deal mainly with

the order of procedures involved in tuning the engine.

Engine Compression Testing

During all work done around the engine, while the engine is running

or being cranked, use extreme care to avoid getting fingers or cloth-

ing caught in any belts, pulleys, or other moving parts.

General Information

6VPA 7748089 English 09-2007

1. Visually inspect stern drive unit for leaks, missing parts or other

obvious defects. Replace deteriorated parts.

2. Compression check: Proper compression is essential for good

engine performance. An engine with low or uneven compres-

sion cannot be properly tuned.

• Operate engine to normal operating temperature.

NOTICE! Engine must not be started and run without water for

cooling.

• Remove any foreign matter from around spark plugs by

blowing out with compressed air.

• Remove and inspect all spark plugs. Install thread-type com-

pression gauge in spark plug hole.

To Prevent Sparking

WARNING!

Failure to disable the ignition system during compres-

sion testing may cause fire or explosion by igniting

gasoline fumes present during cranking and cause per-

sonal injury or death.

—Remove (grey) 2-wire connector, with purple and grey

wires, at ignition coil.

—With choke and/or throttle plates wide open, crank engine

through at least four compression strokes.

Test Conclusion

The indicated compression pressures are considered normal if the

lowest reading cylinder is within 75% of the highest.

Example:

If the highest pressure reading was 140 PSI, 75% of 140 is 105.

Therefore, any cylinder reading less than 105 PSI indicates an im-

properly seated valve, worn valve guides, piston, cylinder, or worn or

broken piston rings. Any cylinder reading 105 PSI or greater is within

specifications, and compression is considered normal.

If one or more cylinders read low, squirt approximately one table-

spoon of engine oil on top of the pistons in the low reading cylinders.

Repeat compression pressure check on the cylinders.

1. If compression improves considerably, the piston rings are at

fault.

2. If compression does not improve, valves are sticking or seating

poorly, or valve guides are worn.

3. If two adjacent cylinders indicate low compression pressures

and squirting oil on the pistons does not increase the compres-

sion, the cause may be a cylinder head gasket leak between

the cylinders. This problem could allow engine oil and/or cool-

ant to enter the cylinders. It is recommended the following quick

reference chart be used when checking cylinder compression

VPA 7748089 English 09-2007 7

General Information

pressures. The chart has been calculated so that the lowest

reading number is 75% of the highest reading.

After checking cylinder compression, repairs should be made as

necessary. Subsequent adjustments to an engine that does not have

proper compression will not measurably improve performance or

correct operational problems. After verifying compression, check ig-

nition and fuel system components.

Ignition System Components

•SparkPlugs

• Spark Plug Leads

• Distributor Cap

• Rotor

• Ignition Coil

• High Tension Lead

• Ignition Switch

• Circuit Wiring and Connectors

Fuel System Components

• Fuel Tank Pickup and Screen

• Fuel Tank Vent

• Anti-Siphon Valve (if equipped)

• Fuel Octane and Quality

• Boat Fuel Lines and Valves

• External Engine Fuel Filter

• Fuel Pump(s) and Line

• Carburetor Fuel Filter or Screen

• Carburetor Adjustments

Compression Pressure Limit in PSI

Max. Min. Max. Min. Max. Min. Max. Min.

134 101 154 115 174 131 194 145

136 102 156 117 176 132 196 147

138 104 158 118 178 133 196 148

140 105 160 120 180 135 200 150

142 107 162 121 182 136 202 151

144 108 164 123 184 138 204 153

146 110 166 124 186 140 206 154

148 111 168 126 188 141 208 156

150 113 170 127 190 142 210 157

152 114 172 129 192 144 212 158

General Information

8VPA 7748089 English 09-2007

• Engine PCV Valve

• Flame Arrestor

All of the above listed components are not necessarily part of an en-

gine tune-up, but must be considered when attempting to correct en-

gine/boat performance problems. Repair or replace components

only as required.

WARNING!

Do not substitute automotive parts. Volvo Penta marine

components meet U.S. Coast Guard regulations for

external ignition proof operation and marine use. Volvo

Penta marine components are specially designed not to

cause ignition of fuel vapors in the bilge or engine com-

partment. The use of automotive parts can result in fire

and explosion and cause personal injury or death.

Intake Manifold Vacuum Testing

Test Procedures

1. Install a vacuum gauge to a good intake manifold source (usu-

ally at the PCV valve port), following the gauge manufacturer’s

instructions. Start and warm up the engine.

2. Observe the vacuum gauge while operating the engine over a

range of engine speeds.

Test Results

1. A steady vacuum reading between 14 and 19in. Hg. (47-64

kPa) at idle indicates an engine in good mechanical condition.

2. A vacuum reading below 14 in. Hg. (47 kPa) at idle, indicates

an engine that is not developing enough vacuum. Further test-

ing for base mechanical problems is needed.

3. Possible causes of low intake manifold vacuum are late ignition

timing, low compression, poor engine sealing, leaks at vacuum

lines and connections or bad MAP sensor.

4. If the gauge fluctuates at idle, possible causes are sticking or

leaking valves, or an ignition miss.

5. If the gauge fluctuates at idle but smooths out as engine RPM

increases, check for bad valves or camshaft.

6. If the gauge fluctuates more with increases engine RPM, check

for weak or broken valve springs, bad valves, ignition miss, or a

leaking head gasket.

7. If the vacuum gauge fluctuates regularly with each engine

cycle, check for a bad valve.

8. If the vacuum reading drops steadily as engine RPM increases,

check the exhaust system between the engine and vertical

drive for restrictions.

VPA 7748089 English 09-2007 9

General Information

9. See table and chart below and on the following page for more

information.

Vacuum Gauge Readings

Pos Condition Reading

ANormal at Idle 14-19 in. Hg. (47-64 kPa)

BLate Ignition Timing 11-17 in. Hg. (37-57 kPa)

CLate Valve Timing 8-15 in. Hg. (27-50 kPa).

DIntake Leak Low but steady reading

ENormal Acceleration Drops to 2 then rises to 25 when throttle is rapidly increased and

decreased.

FWorn Rings Drops to 0, then rises to 22 when throttle is rapidly increased and

decreased

GSticking Valve(s) Normally steady, intermittently flicks downward approx. 4 in. Hg. (13

kPa) from highest level.

HLeaking Valve Drops 2 in. Hg. (6 kPa) from highest reading.

IBurned or Warped Valve Evenly spaced down-scale flicker approximately 5 in. Hg (17 kPa).

JWorn Valve Oscillates Approximately 4 in. Hg. (13 kPa).

KWeak Valve Springs Violent oscillations as RPM increases.

1515

1010

1515

3030

1515

3030

1010

1515

2525

3030

FGH I J

1010

1515

3030

1515

2525

1010

2525

1515

2020

3030

EABCD

1515

2020

3030

2020

2525

1010

2525

3030

KLMNO

In./Hg.

General Information

10 VPA 7748089 English 09-2007

Gasoline Requirements

DANGER!

Gasoline is extremely flammable and highly explosive

under certain conditions. Always stop engine and do

not smoke or allow open flames or sparks near the boat

when refuelling gas tanks. When filling the gas tank,

ground the tank to the source of gasoline by holding

the hose nozzle firmly against the side of the deck filler

plate, or ground it in some other manner. This action

prevents static electricity buildup which could cause

sparks and ignite fuel vapors.

USE ONLY UNLEADED FUEL. Use lead-free gasoline with the fol-

lowing minimum or higher octane specification:

Inside the U.S.: (R+M)/2 (AKI) = 87

Outside the U.S.: (RON) = 90

If fuels with 89 AKI pump posted (93 RON) octane number or higher

are used an increase in power can be expected with EFI models.

Premium fuels contain injector cleaners and other additives that pro-

tect the fuel system and provide optimum performance.

NOTICE! Engine damage resulting from the use of gasoline

with octane 86 AKI (89 RON) and lower is considered

misuse of the engine and will void the engine warran-

ty. Volvo Penta suggests the use of 89 AKI or higher

fuels. These fuels have additives that are beneficial to

maximum engine performance and long life of service

components.

To prevent gum formation and corrosion in the fuel system, use a

Marine Fuel Stabilizer in the gasoline.

Gasoline Containing Alcohol

Many brands of gasoline being sold today contain alcohol. Two com-

monly used alcohol additives are Ethanol (ethyl alcohol) and Metha-

nol (methyl alcohol).

See the Owner’s Manual for you boat to determine if the boat’s fuel

system is compatible with alcohol blended fuels. if it is compatible,

your engine may be operated using gasoline blended with no more

than 10% Ethanol (ethyl alcohol) meeting the minimum octane spec-

ifications.

LImproper Idle Mixture Floats slowly between 13-17 in. Hg. (44-57 kPa)

MRestricted Exhaust Normal when first started. Drops to approx. 0 as RPM increases

NHead Gasket Leak Floats between 5-20 in. Hg. (17-68 kPa)

ODefective Ignition Component Slight float between 14-16 in. Hg. (47-54 kPa)

Vacuum Gauge Readings

Pos Condition Reading

VPA 7748089 English 09-2007 11

General Information

NOTICE! Do not use any gasoline which contains Methanol

(methyl alcohol).

See the boat’s Operators Manual to determine if the boats fuel sys-

tem is compatible with alcohol blended fuels. If it is, your engine may

use gasoline blended with no more than 10% Ethanol (ethyl alcohol)

meeting the minimum octane specification. Do not use any gaso-

line which contains METHANOL (methyl alcohol).

Continued use of METHANOL (methyl alcohol) fuel will cause seri-

ous damage to the fuel system.

If you use gasoline containing alcohol, be aware of the following:

• The engine will operate leaner. This may cause engine prob-

lems such as vapor lock, low speed stalling, or hard starting.

• Alcohol blended fuels attract and hold moisture. Moisture

can cause fuel tank corrosion. Inspect fuel tanks at least

annually. Replace corroded or leaking fuel tanks.

• Frequently inspect non-metallic parts of fuel system and

replace if excessively stiff, deteriorated or leaking.

Fuel leakage can contribute to a fire and/or explosion.

Crankcase Oil

Initial factory fill is a high quality motor oil for API Service SJ. During

the break-in period (20 hours), frequently check the oil level. Some-

what higher oil consumption is normal until piston rings are seated.

The oil level should be maintained in the safe range between the Add

and Full marks on the dipstick. This range represents approximately

1 litre (1 quart). If it is necessary to add or change the motor oil, use

a quality oil with API service category SJ.

NOTICE! Do not fill above full mark. Overfilling results in high

operating temperatures, foaming (air in oil), loss of

power, low oil pressure and overall reduced engine

life.

At the end of the break-in period (20 hours), change the crankcase

oil and replace the oil filter. Refer to Lubrication and Inspection Chart

for recommended oil change intervals.

NOTICE! The use of multi-viscosity oils, such as 10W-30 or

10W-40, is allowed but not recommended.

Draining and Filling the Engine Crankcase

If using Volvo Penta Premium Synthetic Engine Oil, drain and refill

crankcase every 200 hours of operation or once a year, whichever

occurs first.

If using oil other than Volvo Penta Premium Synthetic Engine Oil,

drain and refill crankcase every 100 hours of operation or once a

year, whichever occurs first.

DANGER!

To prevent fire and explosion, always make sure engine

compartment is free of gasoline fumes before using any

spark-producing tools such as the electric drill motor

used with oil withdrawal pump kit.

General Information

12 VPA 7748089 English 09-2007

Check the motor oil level frequently with the dipstick. When oil is to

be changed, remove dipstick and withdraw oil from crankcase

through withdrawal/dipstick tube. The oil withdrawal tube is provided

so oil does not have to be drained into the bilge. Withdraw oil with a

suction pump.

Fill the crankcase to the specified capacity with a quality motor oil la-

belled for service category SJ. When changing motor oil, select from

the following chart the SAE viscosity that matches the temperature

range in which the boat will be operated. If it is necessary to add mo-

tor oil, use motor oil of the same viscosity.

Disregard any reference to multi-viscosity oil printed

on engine. Such reference is intended for automotive

use only and not for marine applications.

NOTICE! Do not fill above full mark. Overfilling results in high

operating temperatures, foaming (air in oil), loss of

power, low oil pressure and overall reduced engine

life.

Oil Filter

Canister type

Replace the oil filter whenever the motor oil is changed. This filter is

a self-contained, screw-on type. To remove, unscrew filter canister

counterclockwise and discard. When attaching a new filter, be sure

the gasket is lightly lubricated with motor oil. Hand tighten only, run

engine and check for leaks. Do not run engine without supplying

cooling water. See Parts Catalog for model and filter requirements.

Temperature Viscosity Recommendations

If the lowest Anticipated

Temperature is:

The Following SAE Viscosity

Oils are Recommended

32° F (0° C) and above SAE 30

0° F (-18° C) to 32° F (0° C) SAE 20W-20

Below 0° F (-18° C) SAE 10

Crankcase Capacities

Model With Filter

3.0GL/GS 4.0 qts. (3.8 liters)

4.3GL/GXi 5.0 qts. (4.7 liters)

5.0GXi 5.5 qts. (5.2 liters)

5.7GL/Gi/GXi/OSi/OSXi 5.5 qts. (5.2 liters)

8.1Gi/GXi/OSi 9.0 qts. (8.5 liters)

VPA 7748089 English 09-2007 13

General Information

Replaceable Element Type

Replace the oil filter whenever the motor oil is changed. This filter is

a replaceable element type that is mounted in a reusable container.

To remove the element, unscrew the filter cap counterclockwise and

lift the element out.

NOTICE! When replacing the element, always replace the O-

ring with a new O-ring.

Slide the element off the filter support and discard according to all lo-

cal environmental regulations. Replace the O-ring on the filter cap.

Slide the new filter element onto the filter support in the filter cap. In-

stall the cap and filter assembly into the canister. Use a 36 mm sock-

et and torque wrench, tighten to 18 ft. lb. (24 Nm)

Power Steering

Maintain the level with Volvo Penta Power Trim/Tilt & Steering Fluid.

Approved power steering fluids such as GM power steering fluid or

Dexron II automatic transmission fluid can also be used. Do not over-

fill the pump reservoir.

Steering System Lubrication

Every 60 days, grease the steering ram with Volvo Penta grease.

Power Trim/Tilt Fluid Level

At the beginning of each boating season, check the fluid level in the

reservoir as follows:

• Level should be between the “MIN” and “MAX” marks on the

reservoir.

• If necessary, add Power Trim/Tilt & Steering Fluid. Replace

the cap and tighten securely.

Off-Season Storage

There are nine steps that must be completed for Off-Season Storage

Preparation

When gasoline engines are removed from service for long periods (2

months or more), it is important that they are correctly stored or pro-

tected (internally). Today’s gasoline blends are not as stable as in

the past and consideration must be given if the fuel will not be used

within a short time or if the engine is being placed in storage. Failure

to properly stabilize the fuel can damage fuel system components

and is not considered as warrantable a defect that would be covered

and repaired under the limited express warranty.

General Information

14 VPA 7748089 English 09-2007

Boat manufacturers should follow the gasoline storage mixture sec-

tion for testing prior to shipment. Fuel stabilizer can be purchased lo-

cally at most marine supply stores.

Limited Use

If the vessels fuel within the tank(s) will not be consumed within a 30-

day period from the time of filling, a gasoline fuel stabilizer must be

added as per the manufacturer’s instructions. This will help prevent

the fuel from breaking down and causing reduced engine perfor-

mance fuel system clogging or damage from uncontrolled combus-

tion.

Storage

If the boat is being placed into storage, a gasoline fuel stabilizer must

be added to the tank(s) as per the manufacturers instructions. The

amount of stabilizer required is determined by the quantity of fuel

and the length of time it will be placed in storage. The maximum pe-

riod that fuel can be stabilized is six months due to limitations of the

stabilizers and fuels.

WARNING!

Any fuel leakage should be corrected immediately to

prevent possible fire and/or explosion.

NOTICE! Do not run engine out of fuel or run the electric fuel

pumps dry more than 20 seconds. Running the elec-

tric fuel pumps dry will cause fuel pump damage.

Step 1. Prepare a storage mixture

In addition to stabilization of the fuel, it is highly desirable to have the

valves and cylinders coated with a light film of oil previously accom-

plished through fogging. Today’s fuel injection manifolds are de-

signed with a complex air channel design that will not allow the

traditional fogging oils to be injected past the throttle plate while run-

ning. The oil will get stuck in the plenum and never reach the cylin-

ders. Together with the stabilizer, two-cycle motor oil can be added

to a fuel mixture for stabilization purposes.

• Using an outboard motor six-gallon fuel tank, add two-cycle

motor oil at a ratio of 50:1 (one pint to 6 gallons) and stabi-

lizer at one ounce per gallon (unless stated otherwise on the

manufacturers label). Mix well.

• Disconnect boat fuel line at engine fuel pump. Attach the

storage mixture fuel tank.

• Connect a suitable engine flush device if the boat is not in

the water.

• Run the engine on the storage mixture for approximately 5

minutes at 1500 RPM. This will ensure that all fuel system

and internal engine components are thoroughly protected.

Do not operate the engine above 1500 RPM as the water

pump demand may exceed the supply, damaging the pump.

• Reduce the engine speed to idle and stop the engine.

• Reconnect the fuel fitting and check for fuel leaks.

VPA 7748089 English 09-2007 15

General Information

Step 2. Change Motor Oil and Oil Filter:

• Engine should first be operated under load until oil is thor-

oughly warmed up. If oil is allowed to warm up before drain-

ing, a more complete draining will be accomplished. In

addition, accumulated impurities will be held in suspension

by the oil and be removed during draining operation.

• Remove motor oil by siphoning it out of oil withdrawal tube.

Follow the procedure under Draining and Filling the

Engine Crankcase.

• Install a new oil filter and fill crankcase with recommended

oil.

NOTICE! Sterndrive must be submerged in water or an acces-

sory flushing adaptor must be used while operating

engine. When using a flushing adaptor, remove pro-

peller before starting engine to prevent accidental

contact with rotating propeller.

• With sterndrive in full down position, run engine at a fast idle

for a few minutes to distribute clean oil through engine.

• Shut off engine and check oil level. Check oil filter gasket for

leaks. Add oil if necessary to bring oil level up to, but not

over, the full mark.

Step 3. Change Drive Lubricant:

Drain and refill with fresh GL-5 Synthetic Gear Lubricant or Mobilube

1 SHC Fully Synthetic SAE 75W-90 (meeting or exceeding MIL-L-

2105C or D, API GL-4 or 5) gear lubricant. Refer to Vertical Drive

Service Manual.

Step 4. Fog Engine:

• Warm up engine to ensure fuel conditioner is throughout fuel

system. Use 1/2 pint (0.24 liter) of Fogging Oil 12 oz. (355

ml) spray can to fog engine.

• Remove flame arrester from carburettor. Following instruc-

tions on container, bring engine up to a fast idle and slowly

pour or spray 2/3 of fogging oil into carburettor. Keep engine

running while pouring fogging oil into carburettor throat.

Step 5. Drain Cooling System

When draining the cooling system, raise or lower the bow of the boat

to position the engine in a level horizontal plane. This will provide

complete drainage of the engine block and manifolds. If the bow is

higher or lower that the stern, some water may be trapped in the en-

gine block or manifolds.

Improper or incomplete draining may result in freeze damage to the

engine, manifolds, sterndrive, or other components. Freeze damage

is not covered under Volvo Penta’s Limited Warranty.

Front

1. Disable ignition system See Engine Compression Testing on

page 5.

2. Remove inlet and outlet hoses from raw water pump and crank

the engine with starter 1-2 revolutions.

General Information

16 VPA 7748089 English 09-2007

3. Reconnect ignition system.

Starboard

4. Disconnect and drain large hose at circulation pump

Port

5. Remove exhaust manifold drain plug. Clear hole with a small

wire to ensure complete drainage.

6. Remove cap from engine flush hose and lower hose into bilge.

Preparation for Boating After Storage

1. Install all drain plugs. Install cooling hoses and clamps. Check

condition of hoses, manifold end caps and clamps. Connect

hoses to engine and tighten clamps securely. Install boat drain

plug, if removed.

2. Remove the distributor cap and rotor. Wipe the inside of the dis-

tributor cap dry with a clean cloth and spray with Corrosion

Spray. Replace the rotor and cap.

3. Clean the battery terminals. With the ignition switch in the

"OFF" position, install the battery and attach the battery cables.

Spray terminals with Corrosion Spray.

4. Open the fuel shut-off valve (if so equipped) and check all

fuel line connections for leaks.

5. Check the flame arrestor and clean if necessary. Reinstall,

make sure all parts are in place and tighten nut securely.

6. Make a thorough check of the boat and engine for loose or

missing nuts and screws. Pump the bilge dry and air out the

engine compartment.

WARNING!

To prevent a possible explosion, operate the blower as

recommended by the boat manufacturer before starting

engine. If the boat is not equipped with a bilge blower,

open engine cover or hatch prior to starting and leave

open until after engine is running.

If operating boat in water, tie boat securely to dock to

prevent forward or backward movement.

When using a flushing adaptor, remove the propeller

before starting engine to prevent accidental contact

with rotating propeller.

7. Test run engine: Launch boat or use a flushing adaptor installed

on Sterndrive.

NOTICE! Do not start engine out of water unless using a flush-

ing adaptor. Always turn water on before starting en-

gine. Control water pressure as full water pressure

may cause damage to supply pump and engine.

8. With engine compartment open, start the engine. Monitor the

voltmeter, oil pressure and water temperature gauges fre-

This manual suits for next models

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