Volvo Penta PENTA User manual

LAYING-UP AND
LAUNCHING GUIDE
VOLVO PENTA DIESEL
AND GASOLINE ENGINES

TIME WELL INVESTED
2
This guide covers most of the items to be checked
and seen to on your engine and drive when laying
up and launching. Although it won’t take more than
a couple of hours of your time each year, your
engine will run more reliably and economically and
use less fuel, with less chance of unnecessary
breakdowns. Life at sea will be safer.
You will find more detailed information in your engine
instruction book and our do it yourself manuals.
Or consult your authorized Volvo Penta dealer, he will
be pleased to carry out your servicing and mainte
nance, if you do not wish to do it yourself. Certain
complicated jobs are, of course, best left to an
authorized dealer since they call for both specialized
knowledge and special tools.
Always use Genuine Volvo Penta Parts. That way
you can be confident that the parts you use will be
of the right quality and fit perfectly. And make sure
you have tools on board and that your on board
repair kit is complete.
Remember the environment –
collect any oil, coolant, degreaser,
paint, etc., and dispose of them
in the proper containers.
The time intervals mentioned by us are only general and can vary
between different engine types. The operator's manual will give you
the proper intervals for your particular engine. However, entirely
different intervals apply, if you use the engine for commercial purposes
or in very polluted waters.

3
Oil and oil filter changes 4
Cooling system 8
Thermostat 10
Impeller 11
Cooling water hoses/E haust hoses 12
Drive belts 13
Fuel system 14
Air filter/Air intake silencer 15
Electrical system 16
Oil changes – drive/reverse gear 18
Drive 20
Propeller 22
Cleaning and painting 23
Ventilation 24
Corrosion protection – inside the engine 25
Ignition system 26
This symbol represents work in
connection with the laying-up season
This symbol represents work in
connection with the launching season
A yellow bo represents warning te t

4
You should change the engine oil and oil filter after
approx. 100 hours of operation, or at least once
per season.
Choose Volvo Penta engine oil which has good
inhibiting qualities and ou will not need to add
an special inhibiting oil for a normal winter la -up.
A new oil filter will remove soot and metal particles
from the oil and prevent unnecessar engine wear.
Genuine Volvo Penta filters are tested and speciall
designed to suit each particular engine t pe.
Run the engine warm before changing
the oil. It is easier to do this when the
boat is still in the water (it can also be
done in connection with engine inhibiting).
Switch off the engine and use an oil bilge pump to
pump out all the engine oil through the dipstick hole.
Change the oil filter and fill up with the right amount
of Volvo Penta engine oil. Also change transmission
oil, please refer to the ”Oil changes – drive/reverse
gear” chapter. Run the engine for a while. Check for
oil leaks.
OIL AND OIL FILTER CHANGES

5
Check the oil level before starting the
engine.

COOLING SYSTEM
6
INHIBITING SEA WATER COOLED ENGINES
Regular maintenance and servicing of the cooling
s stem is an effective wa of preventing damage
from overheating. It is also important to inhibit the
cooling s stem for the la -up season in order to
avoid frost damage and corrosion.
 Work on the cooling system is best carried out
on land. Otherwise there is a risk of water getting
into the boat.
The engine and reverse gear cooling
water ducts must be flushed and
drained off. Detach the suction pipe
from the inside of the shield on the Aquamatic drive
or from the reverse gear. Connect a hose to the
suction pipe and insert it in a bucket of fresh water.
Make sure that the bucket is continually replenished
with fresh water. Let the engine idle until it warms
up enough to open the thermostat.
 Never let the water pump run dry.

77
It is important to let the engine run
for a while, in order to flush away any
sludge and salt that could otherwise
cause rusting. Then switch off the engine. Insert the
free end of the hose into a solution of water and
Volvo Penta coolant. Allow the liquid to circulate for
a while, without the bucket becoming empty. Switch
off the engine and replace the suction pipe.
N.B. Leave the liquid in the system, as it provides
good protection against freezing and corrosion.
Check and clean sea water filter, if fitted.
If you wish to protect the engine over a longer
period than the normal lay up time, use Volvo Penta
emulsifying inhibiting oil, as it is specially designed
for the cooling water ducts. Follow the same proce
dure as above, but empty the system completely, as
the liquid does not offer any protection against frost.
Check that all plugs and drain cocks
are fully closed.
N.B. Some engines have zinc anodes on the plugs
and these act as sacrificial anodes in the cooling
system. An anode must be replaced when about
50% of its volume has been used up.

COOLING SYSTEM
8
INHIBITING FRESH WATER COOLED ENGINES
Regular maintenance and servicing of the cooling
s stem is an effective wa of preventing damage
from overheating. It is also important to inhibit the
cooling s stem for the la -up season in order to
avoid frost damage and corrosion.
 Work on the cooling system is best carried out
on land. Otherwise there is a risk of water getting
into the boat.
The fresh water cooled engine has two cooling
s stems. The engine block and c linder head are
fresh water cooled. But the oil cooler, heat exchanger
and, on some engines, exhaust pipes, are sea water
cooled and should be inhibited in accordance with
the section on sea water cooled engines.

9
Check the freezing point of the coolant
with a hydrometer and top up the cooling
system if necessary. The coolant mixture
looses its corrosion protective qualities with time
and should therefore be changed every other year.
N.B. Avoid mixing different types of coolants since
it drastically diminishes the corrosion protective
qualities.
Do not mix coolant with other additives.
Check and clean sea water filter, if fitted. Inhibit the
sea water cooled part of the engine in accordance
with the section on sea water cooled engines (see
page 7).
Check the level of the fresh water
system and make sure that all plugs
and draining cocks are fully closed.
N.B. Some engines have zinc anodes on the plugs
and these act as sacrificial anodes in the cooling
system. An anode must be replaced when about
50% of its volume has been used up.

THERMOSTAT
10
If our instrument panel has a temperature gauge
ou will be able to see whether the engine sta s at
the right working temperature or not. Excessive
temperatures are often caused b blockage in the
coolant intake, cooling ducts or heat exchanger, or
b a defective impeller. Too low a temperature is
usuall caused b a fault thermostat.
Check the function of the
thermostat by removing it
and placing it with a ther
mometer in a pan of water. Heat the water and see if
the thermostat opens at the temperature indicated in
the operator’s manual. If not, replace the thermostat.

IMPELLER
11
The impeller pumps cooling water through the
engine cooling s stem. It is, therefore, an extremel
vital safet feature. Replace the impeller at least
ever two ears. However, a worn or damaged
impeller must be replaced immediatel . Make a
habit of keeping a spare impeller, and seal for the
impeller pump cover, on board.
After inhibiting, unfasten the sea water
pump cover and remove the impeller.
Rinse it well and keep it in a tightly
sealed plastic bag in a cool place during the lay up
period.
Install a perfect impeller and impeller
cover together with a new seal.

COOLING WATER HOSES /
EXHAUST HOSES
12
As rubber becomes brittle with time, ou should
occasionall check the hoses for an signs of cracks
or damage
 Leaking cooling water hoses are a safety hazard
and can cause the engine to overheat or the boat
to become filled with water.
 Leaking e haust hoses can cause dangerous
e haust fumes on board and allow water to get
into the boat.
Carefully inspect the hoses and clamps
of the cooling system and exhaust
system. Replace those hoses which do
not feel soft and pliable. Tighten all hose clamps.
Check the condition of the hoses and
that all hose clamps are securely
fastened.

DRIVE BELTS
13
Check on the generator belt and the fresh water
pump drive belt a few times a ear to make sure
that the are properl tensioned. Make sure that
the are not cracked or fra ed. A perfect drive belt
gives a better generator charging effect while, at the
same time, reducing the risk of overheating. Alwa s
keep spare belts on board. Genuine Volvo Penta
drive belts last much longer.
Check the condition of the belts.
Replace them if necessary.
After replacement – tighten the belts
and adjust the tension.
N.B. Check the belt tension once more
after a few hours running. Readjust, if necessary,
according to the Operator’s Manual.

FUEL SYSTEM
14
It is important, when overhauling and servicing
the fuel s stem, to consider the safet aspects and
alwa s use Genuine Volvo Penta Parts. It is parti-
cularl important to avoid getting an dirt into the
s stem.
Fill the fuel tank for the lay up
period and you won’t have to worry
about condensation in the tank.
Check before you fill up that there are no special
rules applicable to the site where the boat is laid up,
about the quantity of fuel aboard.
Venting the fuel system (see operator’s
manual) and run the engine warm,
while checking for leaks.
 Switch off the engine immediately if you
discover any leaks.

AIR FILTER /
AIR INTAKE SILENCER
15
If our engine has an exchangeable filter element,
it should be changed at least once per season.
An engine with a clean air filter can work more
efficientl and uses up less fuel.
Use Genuine Volvo Penta filters, the are speciall
designed and tested for each particular engine t pe.
Change the filter element or clean
the air intake silencer. Also replace the
crankcase ventilation filter (if any).

ELECTRICAL SYSTEM
16
Sea air, which can be ver humid and salt , presents
a tough environment for the electrical s stem to
operate in. The electrical s stem of the engine can
be affected b creeping current, oxidation and
voltage drop if ou do not overhaul it regularl .
Make sure that the wires are undamaged and have
not been subjected to bilge water. Otherwise there
is a risk that leakage currents can get to the engine/
drive or to the bilge water in the bilge. Serious
corrosion damage can occur within a short time if
leakage currents knock out the galvanic corrosion
protection.
 Important! A battery will be seriously damaged
if discharged for longer periods. A discharged or
badly charged battery can be ruined by freezing.

17
Remove the battery cables, clean the
cable clamps and apply the appropriate
type of grease to the battery poles.
Check the electrolyte level and charge the batteries.
Batteries discharge when not in use, so you should
recharge the batteries once a month, or once every
two months, depending on storage temperature.
The warmer the storage conditions, the faster the
discharging process. The battery can be left on
board if it is fully charged.
Clean and dry dirty and damp cables.
Spray the connection points, contacts
and fuse holders on the engine and
under the instrument panel with Volvo Penta Univer
sal Oil. Also loosen and clean any oxidized connec
tion points.
Check all fuses and make sure that
there are spare fuses on board.
Connect the fully charged battery and
grease the poles with pole grease.

OIL CHANGES
DRIVE/REVERSE GEAR
18
 It is absolutely vital that you follow the safety
recommendations in the operator’s manual very
carefully when you work with the drive and shield.
Otherwise, you run the risk of seriously hurting
yourself.
Change the oil in the drive/reverse
gear. Be careful to use the right oil
quality. Fill up to the right level and run
the engine for a moment to make the oil circulate.
If the old oil looks grey, it could be the result of
water leaking into the drive. Contact your authorized
Volvo Penta workshop if your oil looks grey.
Check the oil level.

19
If ou have an S-drive, the rubber seal between
drive and engine bed has to be checked ever ear.
If damaged, it must be replaced with a new seal
immediatel . Otherwise it should be changed ever
seventh ear.

DRIVE
20
When replacing the rubber bellows the drive must
be dismounted first. Let our workshop deal with
this. However, if ou feel that ou can manage the
job ourself, be sure to follow the directions in the
do-it- ourself manual ver carefull .
The bellows are subjected to tremendous wear from
movement and from salt and impurities of the air
and water. If water gets in via the drive joint bellows
it can cause extensive direct damage and, in man
cases, also costl subsequent damage. So replace
the bellows regularl (at least ever other ear).
N.B. If the boat is used in fresh water (or brackish
water containing little salt) the drive anode should
be replaced with a magnesium anode.
Carefully check the exhaust bellow and
drive joint bellow, if you have not alrea
dy done so when laying up. Check that
the hose clamps on the bellows are firmly tightened
and lubricate the grease nipples on the drive and
steering fork (use a grease gun).
Reverse gear engines: Check the propeller shaft
seal. Vent the bushing and apply water repellent
grease into the seal.