Volvo Penta HU series Instruction manual

Z~ Safety Warning
This WorkshopManual will alert you to certain procedures that
must be done very carefully. If you ignore this information,
you could...
® injure yourself or people aroundyou
®Injure the boat operator, boat passengers,or
people around the boat
®Damagethe Volvo Penta product or its systems
Understand the following symbolsbefore proceeding:
Z~I Safety Warning
Alerts youto the possibility of dangerand
identifies information that will help pre-
ventinjuries.
identifies information that will help pre-
vent damageto machinery.
Appearsnext to information that controls
correct assembly and operation of the
product.
This WorkshopManual is written for qualified, factory trained
service technicians familiar with the use of Volvo Penta special
tools.
This Workshop Manual tells you how to correctly maintain and
service Volvo Penta products and systems. Whencorrectly
serviced, the Volvo Penta product will be reliable and safe to
operate.
WhenVolvo Penta special tools are called for, use them.
Wherementioned, the tools are required to perform the service
procedure.
If you use service proceduresor service tools that are not
recommendedin this manual, YOUALONEmust decided if
your actions might injure people or damagethe Volvo Penta
product.

Contents
GeneralInformation........................................
3.0 Engine............... . .....................................
4.3, 5.7 Engines.......................... . ..................
5.0, 5.8 FLEngines........................................
5.0, 5.8 Fi Engines.........................................
7.4, 8.2 Engines.......................... ......... ......... .
SteeringSystems- SX....................................
ControlSystems- SX.....................................
Cooling Systems.... .... .................. .......... .........
Engine Removaland Installation - SX..............
Safety............... ..... ..................... . ..................
© 1995 Volvo Penta of the Americas, Inc. All Rights Reserved
i

Thisworkshopmanualis oneof a set of ninethat coversVolvoPentastem
drive models.All nine bookscanbe orderedas a set fromVolvoPenta
Parts. OrderP/N 7788850-1.
Individual workshopmanualscovering these modelsare also available.
Orderthe following part numbersfrom VolvoPentaParts.
® P/N 7788851-9SXDfve Unit andTransomShield
Includes information on TransomShield, UpperGearUnit and LowerGear
Unit service; DriveUnit removalandinstallation; Propellers;andTrim/Tilt hy-
draulic operation.
® P/N 7788856-8 E~g/ne Components
Includes information on Engineservice andtroubleshooting; Engineremoval
andinstallation; Steering systems;Throttle andShift Comrolsystems;and
Cooling systems.
¯ P/N 7788857-6BectffcN &/gnit~n System
IncJudesservice andtroubleshootinginformationon Crankingsystems;Charging
systems;Trim/Tilt electrical systems;Ignition systems;andEngineandInstru-
ment widng diagrams.
¯ P/N 7788858-4Furl System
Includes service and troubleshooting information on all carburetor, MRand
TB! fuel systemsand related components.
¯ P/N 7788852-7MRL~’agno~Manual(5.0 R, 5.8 F~:Si) - Ford
Includes step by step troubleshooting proceduresfor all MFIFord related
componentsand wiring.
, P/N7788853-5TBIDiagimsti
c" Manual(4.3 G~5. 7 Gi) -
Containstroubleshootingproceduresfor all TBI GMmodelsandrelated corn-
ponents.
® P/N 77888550 SP and DPWorkshopManual
Includes UpperGearUnit andLowerGearUnit overhaulprocedures,installa-
tion andremoval.
, P/N 7788854-3MRDiagnostic Manual(7.4 Gi. Z4 G~) -
includes step by step troubleshooting proceduresfor all MFi GMrelated compo-
nents andwiring,
¯ P/N 7788859-0 DPX- Lower Unit Workshop Manual
includes specific information for repair andoverhaulof the DPXLowerunit and
Xact
TM steering systemsnot coveredin the SPand DPWorkshopmanual°
ii

This Volvo Penta Stern Drive WorkshopManual
Covers The Following Volvo Penta "HU"Models
SX
~,
Engine Model Nr. Transom Shield
3.0 GS SX NPS 3868181 38682881SX-LIMITEDTRIM
3,0 GSSX 3868182 3868288/SX-LIMITED TRIM
4.3 GL SX 3868184 3868176/SX-C
4.3 GSSX 3868186 3868178/SX-C
5,0 FL SX 3868189 38681761SX-C
6,0 Fi SX 3868193 3868176/SX-C
6=8 FL SX 3868190 3868176/SX-C
5.8 FI SX 3868194 38681761SX-C
5.8 FSi SX 3868195 3868176/SX-C
H.A. = high altitude applications
DuoProp
®
Engine Model Nr. Transom Shield
4.3 Gi DP 3868320 38682991DP-S
4.3 GSDP 3868321 3868299/DPOS
5.0 FL DP 3868322 38682991DP-S
5.0 F| DP 3868323 3868299/DP-S
5.7 Gi DP 3868325 3868299/DP-S
5.8 FL DP 3868324 3868299/DP-S
5.6 Fi DP* 3868326 38682991DP-S
5.8 FSi DP 3868327 3868299/DP-S
7.4 GL DP 3868328 38682991DP-S
7.4G|DP 3868335 38682991DP-S
t
" = export on!y H.A. = high altitude applications
DPX
~
Engine Model Number Transom Shield
7.4 GSi DPX-CA3868198 3868289/DPX-C
/
7.4 GS| DPX-CB3868198 38682891DPX-C
7.4 GSi DPX-CC3868198 3868289/DPX-C
8.2 GL DPX-CA 3868133 3868289/DPX-C
8.2 GL DPX-CB 3868133 3868289/DPX-C
8.2 GL DPX-CC 3868133 38682891DPX-C
Drive Unit
3868159/SX-CTIl.85:l
3868159/SX-CT/l.85:l
38681601SX-C/1.66:1
3868160/SX-Cll.66"1
3868160/SX-C/1.66:1
38681611SX-CI1.60:1
38681621SX-C/1.51:1
38681621SX-CI1.51:1
38682081SX-CI1.43:1
Drive Unit
3868008/DP-C 112.30:1
3868008/DP-C 112.30:1
3868002/DP-Cl!1.95:1
38680021DP-Cl/1.95:1
38680021DP-C1/1.95:1
38680021DP-C1/t .95:1
3868002/DP-Cl11.95:1
38680021DP=Cl/1.95:1
3868022/DP-D111.78:1
38680221DP-DlI1.78:l
N.A. = Not Available
Drive Unit
38680201DPX-C/1.59:1
3868021/DPX-CI1 °68:1
3868023/DPX-C/1,78:1
3868020/DPX-C11.59:1
38660211DPX-CI1.68:1
3868023/DPX-CI1 o76:1
Options
3868176/sx-c
3868t76/SX-C
3868159/SX-C/1.85:llH.A.
3868159/SX-C/1.85:11H.A.
38681591SX-CI1.85:11H.A.
38681601SX-CI1.66:11HoA.
3868160/SX-CI1.66:11H.A.
38681601SX.CI1.68:11H.A.
3868162/SX-C/1.51:l/H.A.
Options
3868008/DP-C1/2.30:1/H.A.
38680081DP-CII2.30:llH.A.
3868008/DP-C1/2.30:11H.A.
38680081DP-C1/2.30:l lH.A.
3868008/DP-Cl12.30: l lH.A.
38680221DP-D1/1.78:1
38680021DP-C1/1.95: I/H,A.
N.A.

This Volvo Penta Stern Drive WorkshopManual
Covers The Following Volvo Penta "NC" Models
SX"
Engine
3.0 GSSX NPS
3.0 GSSX
4.3 GL SX
4.3 GSSX
5.0 FL SX
5.0 Fi SX
6.7 Gi SX
5.8 FL SX
6.8 FSi SX
ModelNr. TransomShield Drive Unit
3868181 36684321SX-LIMITEDTRIM 38683961SX.CTI1.85:l
3868182 38684321SX-LIMITEDTRIM 38683961SX-CTI1.85:l
3868184 38684041SXIDP 3868395/SXll.66
3868186 38684041SXIDP 3868395/SXI1°66
3868414 3868404/SXIDP 38683951SX/1.66
3868416 38684041SXIDP 3868394/SXl1.60
3868429 38684041SX/DP 3668393/SXI1.51
3868415 38684041SXIDP 3868393/SXI1.51
3868418 38684041SXIDP 38683931SXI1.5t
H.A.= high altitude applications
DuoProp
®’
Engine ModelNr. TransomShield
4.3 GL DP 3868164 38684041SX/DP
4.3 GSDP 3868186 38684041SXIDP
4.3 Gi DP 3868185 38684041SX/DP
6.0 FL DP 3868414 38684641SXIDP
5.0 Fi DP 3868416 38684041SXIDP
6.7 Gi DP 3868429 3668404/SX/DP
8.8 FL DP 3868415 38684041SXIDP
5,8 FSi DP 3868418 38684041SXIDP
7.4 GL DP 3868196 38684041SXIDP
7.4 Gi DP 3868450 38684041SX/DP
* = for export only H.A. = high altitude applications
Drive Unit
3868163/DPI2.30
38681631DPI2.30
38681631DPI2.30
38681641DPI1.95
3868164/DPll .95
38681641DP/1.95
38681641DPIl.g5
3868164/DP/1.95
3868022/DP-D111,78:1
3868166/DPI1.68
N.A. = Not Available
Options
386839711.97/SXC
386404/TSK
386839711.971SXC
386404/TSK
3868465/SXl1.85
3868465/SXI1.65
N.A.
3868395/SXll .66
N.A.
N.A.
N.A.
Options
N.A.
N.A.
N.Ao
N.A.
N.Ao
N.A.
N.A.
38681651DPII.78
N.Ao
N,A.
Engine ModelNr. TransomShield
7.4 GSi DPX-CA 3868198 3868289/DPX
7.4 GSi DPX-CB 3868198 38682891DPX
7.4 GSi DPX-CC 3868198 38682891DPX
8.2 GL DPX-CA 3868133 38682891DPX
8.2 GL DPX-CB 3868133 38682891DPX
8.2 GL DPX-CC 3868133 38682891DPX
Drive Unit
38680201DPX11.59:1
38680211DPX11,68:1
38680231DPXIt ,78:1
3868020/DPX11.59:1
38680211DPX11.68:1
38680231DPX11.78:1
iv

Section 1
General Information
Table of Contents
Belt Adjustments
Alternator .................................... 1-24
Power Steering ................................ 1-22
Raw-water Pump............................... 1-24
Belt Tension .................................... 1-21
CompressionPressure Limit Chart ................... 1-7
conversion Charts
Drill ......................................... 1-39
Metric ....................................... 1-38
Crankcase Oil ................................... 1-9
Engine Break-in .................................. 1-18
Engine compression Testing ........................ 1-5
Engine Troubleshooting Guides ..................... 1-26
Gasolines Containing Alcohol ....................... 1-8
Gasoline Requirements ............................ 1-8
Introduction .................................... 1-2
Lubrication
Inspection Chart ............................... 1-41
Steering System ............................... 1-11
Off-Season Storage Preparations .................... 1-11
Oil Filter ....................................... t-10
PowerSteering Ruid Level ......................... 1-11
PowerTrim/Tilt Fluid Level - SXModels......... ...... 1-11
Preparation for Boating After Storage ................ 1-17
Submerged Engine ............................... 1-20
Symbols ....................................... %40
Torque Specifications, General ...................... 1-37
Troubleshooting - SystemIsolation .................. 1-25
Tune-up Specifications ............................ 1-33
Tuning the Engine ................................ 1-5
20-Hour Check .................................. 1-20
Safety Warning
Before working on anypart of an Volvo Penta®sterndrive, read
the section called Safety at the endof this manual.

introduction
This workshopmanualcoversVolvoPentastern drive models.It is
divided into sections concerning various systemsand assem-
blies. Refer to the Contentsto locate the section covering the
systemor assemblyrequiring service. Eachsection title pagehas
an additional listing that will describethe section’s contentsin
moredetail. Besure to readthe SafetySectionat the endof this
manual,andpay special attention to all safety warningsas they
appearthroughoutthe text. Sincemodelsare subject to changeat
any time, somephotosmaynot depict actual product.
GoodServicePractice
Servicerequired for VolvoPentastern drives is generally oneof
three kinds:
Normalcare andmaintenance-which includes putting a
newstern drive into operation, storing engines,lubrica-
tion, andcare underspecial operatingconditions suchas
salt water andcold weather.
eOperating malfunctions - due to improper engine or
drive mounting,propeller condition or size, boat condi-
tion, or the malfunctionof somepart of the engine. This
includes engineservicing proceduresto keepthe engine
in primeoperating condition.
¯Complete disassembly and overhaul - such as major
serviceor rebuilding a unit.
It is important to determine before disassemblyjust what the
trouble is andhowto correct it quickly, with minimumexpenseto
the owner.
Whenrepairing an assembly,the mostreliable wayto ensurea
goodjob is to do a completeoverhaul on that assembly,rather
than just to replace the badpart. Wearnot readily apparenton
other parts could causemalfunction soonafter the repair job.
Repairkits andseal kits contain all the parts neededto ensurea
completerepair, to eliminate guesswork,andto savetime.
Repair time can also be minimizedby the use of special tools.
Volvo Pentaspecial tools are designedto perform service pro-
ceduresunique to the product that cannot be completedusing
tools from other sources. They also speedrepair work to help
achieveservice fiat rate times. In somecases,the useof substi-
tute tools can damagethe part.
Donot operateengineout of water evenmomentarily,if
operatedin test tank, useproper test wheel.Failure to do so can
damageraw-water pump, overheat engine, or allow excessive
engine RPM.

Preparationfor Service
Properpreparationis extremelyhelpful for efficient servicework.
A cleanworkareaat the start of eachjob will minimizetools and
parts becomingmisplaced. Clean an engine that is excessively
dirty before work starts. Cleaning will occasionally uncover
trouble sources. Obtain tools, instruments andparts neededfor
the job beforeworkis started. Interrupting a job to locate special
tools or repair kits is a needlessdelay.
Z~ Useproper lifting andhandling equipment.Workingon stern
drives without proper equipmentcan cause damageand person-
al injury.
Alwaysuse clean fresh fuel whentesting engines. Troublescan
often betraced to the useof old or dirty fuel.
Service Policy
Whetherwithin or following the warrantyperiod, VolvoPentahas
a constantinterest in their products.
It is VolvoPenta’spolicy to provide dealers with service knowl-
edgeso they can give professional service demandedby today’s
consumer.TheVolvo PentaService Schools, frequent mailing of
ServiceBulletins, Letters andPromotions,Special Toolsandthis
WorkshopManualrepresent VolvoPenta’s efforts to assist deal-
ers in giving consumersthe best and most prompt service
possible. This WorkshopManualcovers all phasesof servicing
the VolvoPentastern drive unit. If a service question doesnot
appearto be answeredin this manual,youare invited to write to
the Volvo Penta Service Departmentfor additional help. Always
be sure to give completeinformation, including engine model
numberand serial number.
Besure that you are familiar with VolvoPenta’sWarranty.if you
haveany questions, write the VolvoPentaService Department.If
other than genuineVolvo Pentareplacementcomponentsor parts
are used, Volvo Penta mayrefuse subsequentwarranty claims
involving that engine.
Whena brand-nameproductor specific tool is called for, another
item maybe used. However,the substitute musthaveequivalent
characteristics, including type, strength, andmaterial. Youmust
determineif incorrect substitution could result in product mal-
function andpersonalinjury to anyone.Toavoid hazards,equiva-
lent products which are used mustmeetall current U.S. Coast
GuardSafety Regulations and ABYCstandards.

ReplacementParts
/~ Whenreplacementparts are required, always use genuine
VolvoPentaparts, or parts with equivalentcharacteristics, in-
cluding type, strength, andmaterial. Failure to do so mayresult
in productmalPdnclionandpossibleinjury to the operatorand/or
passengers.
Parts Catalogs
/~ Parts Catalogsare a goodsourceof information for ordering
parts. Theyare NOTa goodsource for disassemblyandreas-
semblyof the enginesand drives. Theexplodedviews in g-~
PartsCatalogsare for illustxal~on of parts only, not a sourceof
assemblyins~uctJons. Theworkshopmanualhas det=led infor-
mationandis the only sourceof inforn~on for disassemblyand
reassembly.
Fagure to fogow workshop manuai ~ and
cau~nsmayresult in dea~, pemonalinjury to
yourself or bystandersanddamagedequipment.
SpecialServiceTools
VolvoPentahasspecially designedtools to simplify disassembh/
andreassemblyoperations. Thesetools are illustrated in this
WorkshopManual.All VolvoPentaspecial tools can be ordered
from Volvo PentaParts Department.Non-dealerusers of Work-
shopManualsmustorder Special tools through andauthorized
VolvoPentaDealer.
ProductReferences,Illustrations andSpecificadons
VolvoPentareservesthe right to makechangesat anytime,with-
out notice, to specifications, models,andprocedures.Also, the
fight to changeany specifications or parts at anytime without
incurring any obligation to equip sameon modelsmanufactured
prior to date of suchchange.All information, illustrations and
specifications, containedin this manualare basedon the latest
productinformationavailableat the timeof printing. Theright is
reservedto makechangesat any time without notice.
Photographsandillustrations usedin this manualmaynot depict
actual modelsor equipment.Thecontinuing accuracyof this
manualcannot be guaranteed.
SafetyRelated 1-4

Tuning TheEngil~
Thepurposeof an enginetune-up is to restore powerandperfor-
mancethat hasbeenlost throughwearanddeterioration of oneor
morecomponents.In the normal operation of an engine, these
changescantake placegraduallyat a numberof points. It is seldom
advisableto attemptimprovementin performanceby correcting one
or two items only. Lasting results will be obtainedby following a
definite andthoroughprocedureof analysisandcorrectingall items
affecting powerand performance.
Economical,dependableoperation can be ensuredif a complete
tune up is performedonceevery boating season,preferably at the
beginning of the seasonwhenboat is brought out of off season
storage. Componentsthat affect powerand performancecan be
divided into three groups:
e Componentsaffecting compression
¯ Componentsaffecting ignition
eComponentsaffecting fuel system
Proceduresfor performinga completeenginetune-upwill be cov-
eredin this manual.
Engine CompressionTesling
1. CompressionCheck:Proper compressionis essential for good
engine performance. An engine with low or unevencompression
cannotbe properly tuned.
AWAR~ Use~c~earomTd~3~ew/~nx~vgorc~r-
/rig. Remove/oosedo~i~g andjewe/ty to prevent
entangleme~wiU~rotating pulleys andddvebelts.
a. Runengineup to normaloperating temperature.
Engine must NOTbe started and run without water for
cooling.

b. Removeany foreign matter from aroundspark plugs
by blowingout with compressedair.
WARNING HeatingandeyeprotecO’onrequiredto preventinjury
while usingcompressedair.
c. Removeandinspect all sparkplugs. Install thread
type compressiongaugein spark plug hole.
d. To PreventSparking:
¯3.0, GS,4.3 GL,GS,Gi, 5.7 Gi, and7.4 Gi, GSi
Models- remove2-wire connectorfrom d’~uibutor.
¯5.O, 5.8 FL, and7.4, 8.2 GLModels- removeboth
distributor primarywiresfromth~ ignition coil, and
tape wire terminals to preventaccidental ground-
ing.
¯5.0, 5.8 Fi, FSi Models- unplug2-wayconnector
at ignition coil.
e. Withchokeandthrottle plates wideopen,crankengine
throughat least four compressionstrokes, or until com-
pressiongaugereadingstopsrising.
Test Conclusion
Theindicated compressionpressuresare considerednormalif the
lowestreadingcylinderis within 75%of the highestreadingcylinder.
Example:
if the highest pressurereading was140psi, 140 X .75 = 105.
Therefore,anycylinder readingless than 105psi indicates valve,
piston, or piston ring problems.
if oneor morecylinders readlow, squirt approximatelyonetable-
spoon(25 ml) of engineoil in the cylinders with the low readings.
Repeattest on the cylinders with low readings. This is commonly
referred to as a "WetTest."
1. If compressionimprovesconsiderably,the piston rings are at
fault.
2. if compressiondoesnot improve,valves are seating poorly or
bumtvalves are suspect.
if twoadjacentcylinders indicate low compressionpressures,
anda wet test doesnot improvecompressionon either cylin-
der, the headgasket maybe leaking betweenthe cylinders.
This problemmayor maynot be accompaniedby coolant in
the cylinders.If coolantis discoveredin the cylinders,this may
be causefor further investigation on fresh water cooleden-
gines with unexplainedcoolantloss.
3.
A Safety Related 1-6

it is recommendedthe following quick reference chart be usedwhenchecking cylinder compression
pressures. Thechart has been calculated so that the lowest reading numberis 75%of the highest
reading.
CompressionPressureLimit Chart
Max. Min.
PSR PSi
134 101
136 102
138 104
140 105
142 107
144 108
146 110
148 111
150 113
152 114
Max. Min.
PSI PSI
154 115
156 117
158 118
Max. Min.
PSi PSi
174 131
176 132
178 133
Max. Min.
PSI PSi
194 145
196 147
198 148
200 150
202 151
204 153
206 154
208 156
210 157
212 158
160 120
162 121
164 123
166 124
168 126
170 127
172 129
180 135
182 136
184 138
186 140
188 141
190 142
192 144
After checkingcylinder compression,repairs should be madeas
necessary. Subsequentadjustments to an engine that doesnot
have proper compressionwill not measurablyimprove perfor-
manceor correct operational problems.After verifying compres-
sion, checkignition and fuel systemcomponents.
¯ Spark Plugs
¯ Spark Plug Leads
¯ Distributor Cap
¯ Rotor
¯ ignition Coil
¯ High Tension Lead
¯ ignition Switch
¯ Circuit Wiring and Connectors
¯ ECM
¯Fuel TankPickup and Screen
¯Fuel TankVent
¯Anti-SiphonValve (if equipped)
¯Fuel Octaneand Quality
¯Boat Fuel Lines andValves
¯ExternalEngineFuel Filter
¯ Fuel Pumpand Line
¯CarburetorFuel Filter or Screen
¯Carburetor Adjustments
¯EnginePCVValve (if equipped)
¯FlameArrestor
¯PressureRegulatorandinjectors
¯TB! Unit
All of the abovelisted componentsare not necessarilypart of an
engine tune-up, but must be considered whenattempting to
correct engine/boat performanceproblems. Repair or replace
componentsonly as required.
___~Donot substitute automotiveparts. VolvoPenta marine
componentsmeetU.S. Coast Guardregulations for external
ignition proof operation andmarineuse. VolvoPentamarine
componentsare specially designednot to causeignition of fuel
vaporsin the bilge or enginecompartmentTheuse of automo-
tive partscanresult in fire andexplosion,
s~+.~,~ Z~ Safety Related 1-7

Gasoline Requirements ,
Volvo Penta modelsare designedfor maximumperformancewith the
use of lead-free gasolinewith the following minimumor higher octane
specification:
Inside the U.S., (R+ M)/2(AKI)
Outsidethe U.S., (RON)-
4.3 GLModels- Theignition timing will haveto be retardedif lower
octanefuels, with minimum86 AKI {90 RON)octane, are used. Refer
to "Timing"in Tune-upSpecifications.Whenignition timing is retarded,
a slight decreasein powercanbe expected.
Useof gasolinewith lower than 89 AKI (93 RON)octanein 4.3
models,withoutretardingignition timingasspecified,will result in seri-
ous damageto your engineandwill void the enginewarranty.
All Other Models- Loweroctanefuels, with minimum86 AKI (90 RON)
octane, canbe used. With the use of lower octanefuel, a slight de-
creasein powercan be expected.
Enginedamageresulting from the use of gasoline with octane
lowerthan 86 AKI{90 RON)is consideredmisuseof the engineandwill
void the enginewarranty.
Somemarinassell fuel with lead addles.Donot use leadedfuel as it
mayplug the fuel injecton. Premiumfuel containsinjector cleanersand
other additives that protect the fuel systemandprovideoptimumper-
formance.Theuse premiumgradefuels in all moddsis s~onglyrecom-
mended.To prevent gumformation and corrosion in the fuel system,
useFuel Conditionerin the gasoline.Fuel Conditioneris available from
your VolvoPentastemdrive dealer.
i
A Gasoline is extremely flammableand highly explosive under cer-
tain conditions, Alwaysstop engine anddo not smokeor allow open
flames or sparks near the boat whenrefueling gas tanks. Sparksor
flamesmaycausean explosionresukingin personalinjury.
A WhenfilSng the gastank, groundthe tank to the sourceof gasoline
byhdc6ngthe hosenozzlefirmly againstthe side of thedeckfiller plate,
or groundit in someother manner.Thisactionpreventsstatic electricity
build-up whichcould causesparks andignite fuel vapors. Sparksor
flamesmaycauseanexplosionresultingin personalinjury.
GasolinesContainingAlcohol
Manygasolines being sold today contain alcohol. Twocommonlyused
alcoholadditives are Ethanol(ethyl alcohol} andMethanol(methylalccP
hol).
A Safety Related 1-8

Seethe boat’s OperatorsManualto determineif the boat’s fuel
systemis compatiblewith alcohol blendedfuels. If it is, your
engine may use gasolines blended with no more than 10%
Ethanol (ethyl alcohol) meetingthe minimumoctane specifica-
tion. Do not useanygasoline which contains METHANOL(meth-
yl alcohol).
[~ Continued use of METHANOL(methyl alcohol) fuel will
causeserious damageto the boat or enginefuel systems.
if youusegasolinecontainingalcohol, be awareof the following:
Theengine will operate leaner. This maycauseengine
problemssuchas vaporlock, low speedstalling, or hard
starting.
Alcohol blendedfuels attract and hold moisture. Mois-
ture cancausefuel tank corrosion. Inspect fuel tanksat
least annually. Replacecorrodedor leaking fuel tanks.
¯Frequentlyinspect non-metallicparts of fuel systemand
replaceif excessivelystiff, deterioratedor leaking.
Z~ Fuel leakagecan contributeto a fire and/orexplosion.
CrankcaseOil
[~] Initial factory fill is a high quality motoroil for APi Service
SG/CD.During the break-in period (20 hours), frequently check
the oil level. Somewhathigher oil consumptionis normal until
piston rings are seated.Theoil level shouldbe maintainedin the
safe rangebetweenthe AddandFull markson the dipstick. This
rangerepresentsapproximately1 liter (1 quart), if it is necessary
to addor changethe motoroil, usea quality oil with API service
category SG/CDthat meetsGenera/MotorsStandard GM-6094-M
or Ford Specification ESE-M2C153-E.Volvo Penta DuraPlus
TM
Motor Oils are recommended.
At the endof the break-in period (20 hours), changethe crankcase
oJi andreplacethe oil filter. Referto LubricationandInspection
Chart for recommendedoil changeintervals.
Theuseof multi-viscosity oils, suchas 10W-30or 10W-40,
is not recommended.
Draining and Riling the EngineCrankcase
Drain andrefill crankcaseevery100hoursof operationor oncea
season,whicheveroccursfirst.
Z~ To prevent fire and explosion, always makesure engine
compartmentis free of gasolinefumesbefore using any spark-
producingtools such as the electric drill motorusedwith oil
withdrawal pumpkit. Fire andexplosioncanresult in personal
injury.

~ Check the motor oil frequently. Whenoil is to be
changed,removedipstick anddrawoil from crankcasethroughdip-
stick t"ube with a suction pump.Thedipstick tube is intendedto be
usedfor drainageof theengineoil soit will not haveto bedrainedinto
thebilge.
Fill the crankcaseto recommendedcapacity with a quality motoroil
labeled for SAEservice category SGwhich meetsGeneralMotors
Standard GM-8094-Mor Ford Specification ESE-M2C153-E.Oils
conformingto this standardcontaindetergentandanti-wearadditives
that will prolongenginelife. VolvoPentaDuraPlus
TM SyntheticMotor
Oil P/N3851230-7exceedsboth manufacturersstandards.
Whenchangingmotoroil, select the viscosity that matchesthe tern-
perature range in which the boat will be operated. Usethe same
viscosity whenaddingmotoroil, donot mixdifferent viscosity oils.
32°F (O°C) and above SAE 30
0°F (-18°C) to 32°F (0°C) SAE 20W-20
Below0°F (-’18°C) SAE 10W
Donot fill abovefull mark.Overfilling results in highoperatingtern-
peratures,foamingthe oil (mixingair in the oil), loss of power,and
reducedenginelife.
3.0 GS .... 3.5qts.(3,3liters)
4.3 GL,GS,andGi 4.0qts.(3,8liters)
5.0 FL 5.0qts.(4,7liters)
5.7 Gi 5.0qts.(4,7Riters)
5.8 FL 5.0qts. (4,7I~ers)
5.0Fi 5.0qts.(4,7liters)
5.8Fi, FSi 4.0qts.(3,8liters)
7.4, 8.2 GL 6.0qts.(5,7liters)
7.4Gi, GSi 8.0qts.(7,5liters)
~th Filter
4.0qts.(3,8liters)
4.5qts.(4,3liters)
6.0qts. (5,7liters)
6.0qts. (5,7liters)
6.0qts.(5,7liters)
6.0qts.(5,7liters)
5.0qts.(4,7liters)
7.0qts.(6,6Eiters)
9.0qts.(8,5liters) N
34101
..,~.:: ; ::.-_,_~,~._%,-~"~~-’ -’,;.0,,~:%j:.~,._~-~l= .
[~ Replacethe oil filter wheneverthe motoroil is changed.This
filter is a self-contained, screw-ontype. Toremove,unscrewfilter
canister counterclockwiseanddiscard. Whenattaching a newfilter,
be sure the gasketis lightly lubricated with motoroil. Handtighten
only, run engine and check for leaks. Donot run engine without
suppling cooling water. See Tunsmp $~~ns for model and
filter requirements. 1-~ 0

PowerSteering Fluid Level
[~ ~] Maintain the level With Volvo Penta power trin~ilt &
steering fluid. Approvedpowersteering fluids such as GMpower
steering fluid or DexronII automatictransmissionfluid can also
be used. Donot overfill the pumpreservoir.
Steering SystemLubrication
[~] [~ Every 60 days, grease the steering ram ~) with Volvo
Penta Grease.
PowerTrim/Tilt-Fluid Level - SX Models
7L~_JAt the beginningof eachboating season,checkthe fluid
level in the reservoir as follows:
/~ Thetrim/tilt hydraulicsare pressurizedwhenthe drive unit is
in the downposition. Thedrive unit mustbe tilted fuji up to
relieve hydraulicpressurebeforeremovinglevel/fill plug (~.
Failure to tilt the drive unit to the full upposition before
removinglevel/fi|l plug wouldresult in a hazardoussprayof
hydraulic oil. Cautionshouldalwaysbe taken whenremoving
level/fill plugbyplacing8 ragoverthelevel/fill plugto prevent
residualpressurefromsprayingoil,
1. Withthe drive unit tilted full up, slowly andcarefully remove
thelevel/fill plug.
2. Checkthe fluid level. Thefluid shouldbe level with the bottom
of thefill holewhenthe drive unit is at full tilt. If necessary,add
VolvoPentapowertrim/tilt & steeringfluid. Replacethe level/fill
plug andtighten securely.
Off-Season Storage Preparations
[~ Thereare nine steps that mustbe completedfor off-season
storage preparation.
Step 1. Condition Fuel System:
AddFuel Conditioner to fuel system.Follow instructions for
adding conditioner and running engine as stated on the con-
tainer. This will stabilize the fuel andprevent formation of
varnish andgumin entire fuel system.Dothis before continu-
ing with the following procedures.
[~ Models equipped with 4 BBLcarburetors should be run
under a load at a high enoughthrottle setting to circulate
conditioner through the secondaryfuel system.
E.~,~ ~ Safety Related 1-11
24074
COA6781A

Step2. ChangeMotorOil andOil Filter:
eEngineshould first be operatedunderload until oil is
thoroughly warmedup. if oil is allowed to warmup
before draining, a morecompletedraining will be ac-
complished.In addition, accumulatedimpurities will be
held in suspensionby the oil and be removedduring
draining operation;
Removemotoroil by siphoning it out of oil withdrawal
tube. Follow the procedureunder Draining and Filling
the EngineCrankcase.
Install a newoil filter andfill crankcasewith recom-
mendedoil. With drive unit in full downposition, run
engineat a fast idle for a fewminutesto distribute clean
oil throughengine.
Shutoff engineandcheckoil level. Checkoil filter gasket
for leaks. Addoil if necessaryto bringoil level upto, but
not over, the full mark.
Drive unit mustbe submergedin water or an accessory
flushing adaptor mustbe usedwhile operating engine.
Whenusinga flushing adaptor, removepropeller before
starting engineto prevent accidental contact with moving
propeller. If propeller is not removed,personalinjury may
result.
Step3. ChangeDrive Unit Lubricant:
Drainandrefill with fresh DuraPlussynthetic GL5gearoil. Refer
to Drive Unit WorkshopManual
Step4. FogEngine:
Carburetedand TBI Models
Warmup engineto ensurefuel conditioner is throughout
fuel system.Use1,~ pint (0,24 litre) of FoggingOil or
oz. (355mi) spray canto fog engine.
eRemoveflame arrestor from carburetor. Following in-
structions on container,bring engineup to a fast idle and
slowly pour or spray %of fogging oil into carburetor.
Keepengine running while pouring fogging oil into
carburetorthroat.
Rapidly addremaining1~ of fogging oil to carburetor,
then reducethrottle to idle andlet enginedie. Turnoff
ignition andreplace flame arrestor. Closefuel shutoff
valve (if so equipped).
)/~ Safety Related 1-12

Fi Models
Preparingan engine"storagemixture"in a six gallon fuel tank.
It mustconsistof a 5 gallons(! 8,9liters) fuel; 4 pints (64oz.,
1892.7ml) FoggingOil; and1/3 cup (2.5 oz., 73.9 ml) Fuel
Conditioner.Mix theseingredients thoroughly.
¯Disconnect fuel line at the engine. Connectthe
"storage mixture" and run engine .for approxi-
mately 5 minutes at 1500 RPM.This will ensure
that all fuel systemsand internal engine compo-
nents are thoroughly protected. Shut off engine
before the "storage mixture" is depleted.
ACAUTION Donotrunengineout of fuel. Thee/ectric fuel
pumpswJ be damaged~
Step 5. Drain Cooling System:
CAUTIONWhendra/n/ng en,~ne, ra~e orlower the bowto
engine in a ho~ontal plane. This wi
providefor completedrainageof blockandmani-
folds, ff bowof boat is tu’gher or lower than
stern, somewater maybe trapped in the en~ne
Nockor mmdfoids.Improperor incomp~=Wdrain-
ing mayresult in freeze d~,nageto the en~e,
manifolds, drive unit or other components.
FREEZE DAMAGEIS NOT COVEREDUNDER
VOLVOPENTA"S L/M/TED WARRANTY.
’~ nPt3
[~] Front
Loosenandslide clampback. Removeanddrain long hose
at thermostathousing.
Disconnectan drain large hoseat circulating pump.
[~] Port
@Removeexhaustmanifold petcock stem. Clear hole with a
small wire to ensurecompletedrainage.
Removecylinder block petcock stem. Clear hole with a
small Wireto ensurecompletedrainage.
34093
Front
Disconnectanddrain long hoseat thermostathousing.
®Disconnectanddrain large hoseat circulating pump.
1-13

[~ Starboard
@Loosenclamp and removehose.
~) Removecylinder block petcock stem.
wire to ensurecompletedrainage.
Port
® Loosenclamp and removehose.
® Removecylinder block petcock stem.
wire to ensurecompletedrainage.
Clear hole with a small
Clearhole with a small
~
5.0 and5.8 Fi, FSi Models
Front
Disconnectthe lower water bypasshoseat large diameterof
check-valve.
¯Drainor blowout check-valveandshort hoseto
thermostathousing.
¯ Drain or blowout longhoseto fuel reservoir. 341O2
All 5.0 and5.11 Models
Front
Disconnectanddrain long hoseat thermostathousing.
Disconnectan drain large hoseat circulating pump.
Starboard
® Loosenclamp and removerubber hose.
®Removecylinder block petcock stem. Clear hole with small
wire to ensurecompletedrainage.
34161
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