Volvo Penta 5.7 Gil-B User manual

OPERATORS MANUAL
5.7 GiI-B, 5.7 GiI-C
5.7 GXiI-C, 5.7 GXiI-D
8.1 GiI-B, 8.1 GiI-C
8.1 GXiI-B, 8.1 GXiI-C

1
Welcome Aboard
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 manufacturing to support activities in Parts,
Service, and Sales, high standards have been set to
ensure your pride and satisfaction 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, service requirements and replacement parts.
Please contact your nearest authorized Volvo Penta
dealer for assistance.
We wish you many pleasant voyages.
Our Core Values:
Quality, Safety, Environmental Care
The values and qualities that Volvo Penta expresses are
what make the company unique. From the very begin-
ning, safety and quality have stood at the heart of the
development of all of our products, processes, and
services. It is on these values and qualities that the Volvo
Penta corporate identity, brand position and legal status
have been founded. Today’s core values of quality, safety,
and care for the environment remain central to Volvo
Penta. They express what we believe in as a company
and will ultimately help us to survive.
Quality is a value that traditionally referred to product
quality but now encompasses all aspects of our products
and 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
environmental values.
Environmental Care in all operations, from design to
production, distribution, service, and recycling, is an
integral part of the Volvo quality commitment towards
customers, employees, and the community. By embrac-
ing 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
environmental 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, incorrect 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
procedures, 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 engine 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 recommends the use of biodegradable
degreasing agents for all cleaning. Always dispose of
engine and transmission oil waste, old paint, degreasing
agents and cleaning residue etc. at proper disposal
areas so that they do not harm the environment.
Adapt speed and distance during your boat trips so that
swell and noise generated by the boat do not disturb or
harm wildlife, moored boats, docks, etc. Wherever you
land or cruise, please show consideration and always
leave the areas you visit as you would like to find them
yourself.
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2
Contents
Safety Precautions .............................................. 3
Introduction ......................................................... 5
Power Ratings ................................................... 5
How Load Conditions Affect the Speed of a
Planing Hull ....................................................... 5
“Wagon-Back” Effect ......................................... 6
Your New boat ................................................... 6
Boater’s Responsibilities ................................... 6
Planning Your Trip .............................................. 6
Safety Equipment ............................................. 7
Basic Safety Rules of Boating .......................... 7
High Performance Boat Operation ..................... 7
Certified Engines .............................................. 8
General Information ............................................ 9
Identification Numbers ...................................... 9
Owner’s Identification Card................................ 9
Volvo Action Service (VAS) ............................ 10
Doing Your Own Maintenance and Repairs ...... 10
Parts and Accessories .................................... 10
Volvo Penta Dealer Network ............................ 11
Volvo Penta on the Internet ............................. 11
Warranty Information ....................................... 11
Warranty Registration Form ............................. 11
Features ............................................................ 12
Transmissions .................................................. 30
Instrumentation ................................................ 32
1. Tachometer .................................................. 32
2. Temperature Gauge ..................................... 32
3. Oil pressure Gauge ..................................... 32
4. Voltmeter ..................................................... 32
5. Instrument Lighting ...................................... 32
6. Fuses, 8 Amp ............................................. 33
7. Ignition Switch............................................. 33
Emergency Stop Switch.................................. 34
Controls ............................................................. 35
Maneuvering ................................................... 35
Disengaging the Shift Function ....................... 35
Adjustment of Friction Brake ........................... 36
Starting the Engine ........................................... 37
Preparations .................................................... 37
Starting ........................................................... 38
If Engine Floods .............................................. 38
Operation ........................................................... 39
Checking Instruments ..................................... 39
Oil Pressure .................................................... 39
Engine Coolant Temperature ............................ 39
Charge ............................................................ 39
Engine Protection Mode .................................. 40
Master/Slave Installation................................. 40
High Altitude Operation ................................... 40
How to Shift and Control Speed ...................... 41
Twin Unit Maneuvering .................................... 41
Cruising Speed................................................ 42
After use ............................................................ 43
Stopping the Engine ........................................ 43
Safety Measures ............................................. 43
Salt Water Operation ....................................... 44
Cold Weather Precautions ............................... 44
Laying-up in Water ........................................... 44
Laying-up on Land ........................................... 44
Maintenance Schedule ...................................... 45
Maintenance and Care ..................................... 46
Engine ............................................................... 46
Belt Adjustment .............................................. 46
Oil Level: Checking and Topping-up ................. 47
Oil and Oil Filters: Replacement ...................... 47
Cooling System ................................................. 48
Draining Cooling System (Raw Water System) 48
Draining The Cooling System (Optional Closed
Cooling System) ............................................. 49
Impeller: Checking & Replacing ....................... 49
Cooling System: Inhibiting ............................... 50
Fuel System....................................................... 51
Fuel: General .................................................. 51
Fuel Cell ......................................................... 52
Fuel Injection .................................................. 52
Flame Arrestor ................................................ 52
Fuel Filter: Replacement ................................. 53
Electronic Engine Control ................................ 54
Ignition System ................................................. 54
Spark Plugs .................................................... 54
Ignition Cables and Distributor Cap ................. 54
Electrical Systems ............................................ 55
Electrolytic Corrosion ...................................... 56
Main ON/OFF Power Switch ........................... 57
Battery: Maintenance ...................................... 57
Connecting and Disconnecting ........................ 57
Cleaning .......................................................... 58
Electrolyte Level ............................................. 58
Battery: Charging ............................................ 58
Engine Alignment ............................................. 59
Laying-up & Launching ................................... 60
Inhibiting ......................................................... 60
Laying-up ........................................................ 60
Launching ....................................................... 61
Painting the drive and underwater hull ............. 62
General ........................................................... 62
Underwater Hull ............................................... 62
Engine Flush ................................................... 62
Troubleshooting ................................................ 63
Technical Data .................................................. 64
Fuel Specification. .......................................... 66

3
This owner’s manual contains information you need to
operate 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
information concerning the engine and drive: model
identification, preventive maintenance recommenda-
tions, 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 informa-
tion must be passed to the new owner. The
service information provided in the manual
gives the owner important information about
maintaining the engine and transmission.
If you do not understand or are uncertain about any
operation 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 opera-
tion.
NOTE! Federal law requires manufacturers to notify
owners in the event that a safety related defect
is discovered on any of their products. If you
are not the original owner of this engine, please
notify us at our address listed elsewhere in this
manual, 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.
Carefully observe the safety alert symbols shown for
dangers, 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 opera-
tor, boat occupants, and/or others.
WARNING!
Failure to comply with a warning may result in
injury or death to boat operator, boat occu-
pants and/or others.
CAUTION!
Failure to comply with a caution may result in
failure or damage to the equipment.
Below is a summary of the risks and safety precautions
you should always observe or carry out when operating
or servicing the engine:
1. Check that the warning or information decals on the
engine are always clearly visible. Replace decals
that have been damaged or painted over.
Safety Precautions
2. Always turn off the engine before starting service
procedures. 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 operations before starting the engine. Make
a point of familiarizing yourself with other risk
factors, such as rotating parts and hot surfaces
(exhaust manifold, starter, etc.).
5. Approaching a running engine is dangerous. Loose
clothing or long hair can get caught in rotating parts
and cause serious personal injury.
6. If so equipped, turn off the power supply to the
engine at the main switch and lock it in the
OFF
position 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
engine, open the filler cap slowly and release
coolant system pressure gradually; otherwise,
steam or hot coolant can spray out.
9. Stop the engine and close or block the sea water
intake before carrying out operations on the engine
cooling system.
10. Only start the engine in a well-ventilated area. If
operating the engine in an enclosed space, make
sure your work area is well ventilated.
11. Anticorrosion and antifreeze agents can be hazard-
ous to health and to the environment. Whenever you
use these agents, follow the manufacturer’s instruc-
tions 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 packaging. Ensure that ventilation in
the work place is good. Use a protective mask when
spraying.
13. Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before beginning to work on it. Never start
or operate the engine with the oil filler cap removed;
otherwise, hot oil could spew out.

4
14. Never allow an open flame or electric sparks near the
battery or batteries. Never smoke in proximity to the
batteries. The batteries give off hydrogen gas during
charging which, when mixed with air, can form an
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 battery 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 immedi-
ately using plenty of water and soap. If battery acid
comes in contact with the eyes, immediately flush with
an abundant amount of water and obtain medical as-
sistance.
17. To ensure safe handling and to avoid damaging en-
gine components on top of the engine, use a lifting
beam to raise the engine. All chains and cables should
run parallel to each other and as perpendicular as pos-
sible in relation to the top of the engine. Always check
that lifting equipment is in good condition and has suf-
ficient load capacity to lift the engine and any extra
equipment installed.
18. If extra equipment is installed on the engine, which al-
ters its center of gravity, a special lifting device is re-
quired to achieve the correct balance for safe handling.
19. Never work on an engine that is suspended on a hoist.
20. Components in the electrical, ignition, and fuel systems
on Volvo Penta products are designed and constructed
to minimize the risk of fire and explosion. Using non-
original Volvo Penta parts that do not meet the above
standards can result in fire or explosion on board.
Damage caused by using non-original Volvo Penta re-
placement parts will not be covered under any warranty
provided by Volvo Penta.
21. Fuel filter replacement should be carried out on a cold
engine to avoid the risk of fire caused by fuel spilling
onto the exhaust manifold. Always cover the generator
if it is located under the fuel filter. The generator can be
damaged by spilled fuel.
22. Always use protective gloves when tracing leaks. Liq-
uids ejected under pressure can penetrate body tissue
and cause serious injury.
23. Always use fuel recommended by Volvo Penta. The use
of lower quality fuels can damage the engine. Poor fuel
quality can also lead to higher maintenance costs.
24. Never use a high-pressure washer when washing the
engine.
Safety Precautions

5
Introduction
Power Ratings
A great number of environmental factors, such as baro-
metric pressure, ambient temperature, humidity, the
quality of fuel, and exhaust back pressure can affect
engine performance. When it comes to quoting and
comparing ratings, it is important that there is a unified set
of standards for measurement.
In September 1989, all major marine engine manufactur-
ers agreed to quote engine power output according to a
common set of conditions. These conditions are referred to
as
ISO 8665. All Volvo Penta engines meet the ISO 8665
standard. This ISO standard outlines the following fixed
values or common conditions for determining the rating of
the engine.
Condition Value
Sea water temperature . . . . . . . . . . . . . . . . . . 25°C (77°F)
Fuel temperature . . . . . . . . . . . . . . . . . . . . . . 40°C (104°C)
Air temperature . . . . . . . . . . . . . . . . . . . . . . . . 25°C (77°F)
Exhaust back pressure . . . . . . . . . . . . . 10 kPa (1.45 PSI)
Barometric pressure . . . . . . . . . . . . 100 kPa (14.504 PSI)
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 com-
bustion.
Marine engines can be rated according to one of several
power standards, but power output itself is quoted in
kilowatts (KW) or horsepower (HP), for a given engine
speed, usually at maximum revolutions per minute (RPM).
How Load Conditions Affect the Speed of
a 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 semiplaning hulls.
For example, a new boat tested with fuel and water tanks
only half filled, and without any load, can easily drop 2 to 3
knots in speed when tested fully fuelled and loaded with all
normal equipment and supplies for safe and comfortable
cruising. This is because the propeller installed originally is
frequently one that is designed to give maximum speed
when the boat is new. For this reason it is often advisable
to reduce the propeller pitch by as much as an inch or
more in order to counter the effects of the increase in
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 enhanced acceleration.
In considering the influence of weight, it is worth remem-
bering that fiberglass boats absorb a significant amount of
water into their hulls while left afloat for any length of time
and so become progressively heavier. Another negative
influence on boat performance is marine growth beneath
the waterline - a problem that is often overlooked.

6
Introduction
“Wagon-Back” Effect
As long as we continue to use combustion technology for
engines, there will be exhaust emissions. Despite the
substantial reductions achieved in modern engines, as fuel
burns exhaust emissions and fumes will always be given
off.
But there is also another effect. Any shear-bodied object
moving forward will create a phenomenon we call
“wagon-back effect.” Due to a difference in air pressure,
the airflow behind such an object will have a tendency to
draw dirt and exhaust emissions back into the object.
(You’ll frequently see evidence of this in the excess of road
grime that is drawn back onto the rear windows of cars
and trucks.) 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 afterdeck. Often people will
make the mistake of opening a ventilator or port hole in
order to remove the fumes, but it has the opposite effect —
more fumes are drawn in, and conditions merely become
worse. In high concentrations these fumes may be hazard-
ous. If you suspect that your boat exhibits this “wagon-
back” effect. Please contact your Volvo Penta dealer.
Your New boat
Every new boat has it’s own special characteristics. Even
experienced boat owners should note carefully how a boat
behaves at different speeds, weather conditions, and
loads. Your boat owner’s manual contains information to
help you operate it with safety and pleasure. It contains
details of the boat, equipment supplied or fitted, systems,
and 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 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 Mainte-
nance Schedule. ) The owner/operator must keep records
of all maintenance services performed. This record of
proper maintenance may be required to determine war-
ranty coverage on certain repairs and should be trans-
ferred to each subsequent owner. If you are not sure of the
proper maintenance procedures, contact the Volvo Penta
Consumer Affairs Department at the address found
elsewhere in this manual.
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 equip-
ment 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
maintenance of the boat.
qGet up-to-date charts for the planned route.
qCalculate distance and fuel consumption.
qNote places where you can refuel along your
planned course.
qTell friends or relatives about your route (that is,
file a “float plan”).
21170

7
Introduction
Safety Equipment
qRescue and emergency items such personal flotation
devices and signal rockets. Make sure all passengers
know where these items are.
qReplacement parts.
qProper tools.
qFire 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
passengers at all times.
• Know the “rules of the road” and obey them. If you are
not familiar with the “rules of the road,” take the U.S.
Coast Guard’s boater safety course. You may find
information about boating safety at
WWW.USCGBOATING.ORG and
WWW.CGAUX.ORG/CGAUXWEB/PUBLIC/
PUBFRAME.HTM.
• Prevent explosion and fire by maintaining your fuel
delivery system in top condition. Fuel vapor is volatile;
handle fuel with care.
• Keep your boat and equipment neat and in top
operating condition. Carry a selection of spare parts
for the engine. (Volvo Penta’s on-board 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 in waters that are unfamiliar, obtain
appropriate charts to avoid damage from underwater
objects.
High Performance Boat Operation
High performance is not only defined by engine size, but
by a combination of engine power (horsepower), hull
design, and the size of the boat. Your new engine(s)
produce a high power output. Depending on the boat type,
the top speed may be much higher than what you are
accustomed to.
High speed operation requires an experienced operator
who has mastered handling of high performance boats. It
is advisable 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
boaters may not realize the speed at which you are
traveling, especially when you close in on another boat
from astern or from ahead. Always keep a good distance
to allow for the unexpected! Always be prepared for what
other boaters may do unexpectedly. High speed driving
requires the driver to give a high degree of attention to
boat operation and surrounding conditions.
A boat traveling at a speed of approximately 70 M.P.H. (60
knots) covers about 101 feet (30 meters) in 1 second. The
faster you go the quicker things will happen. High speed
driving requires a lot of water and a good distance from
possible hazards! Always allow for adequate reaction time.
Always reduce speed when visibility is reduced for what-
ever reason.
When driving, make sure that all passengers are safely
seated. Emphasize this especially if you have a larger,
high performance cabin cruiser where one normally moves
about during operation. Reduce speed considerably, or
stop completely 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 approxi-
mately 325 feet (100 meters) before dropping through the
planing threshold and stopping!

8
Certified Engines
If you own an engine certified for any area where exhaust
emissions are regulated by law, the following is important:
Certification means that an engine type is inspected and
approved by the authorities. The engine manufacturer
guarantees that all engines manufactured of that type
correspond to the certified engine. This places special
requirements for maintenance and service as follows:
• The maintenance and service intervals
recommended by Volvo Penta must be observed.
• Only genuine Volvo Penta replacement parts may be
used.
• The servicing of ignition, timing, and fuel injection
systems must always be carried out by an authorized
Volvo Penta workshop.
• The engine must not be modified in any way except
with accessories and service kits approved by Volvo
Penta.
• No modifications to the exhaust pipes and air supply
ducts for the engine may be undertaken.
• Seals may only be broken by authorized personnel.
Otherwise the general instructions contained in the
Instruction Manual concerning operation, service, and
maintenance must be followed.
NOTE! Late or inadequate maintenance/service or the
use of spare parts other than Volvo Penta original
spare parts will invalidate Volvo Penta’s responsi-
bility for the engine specification being in accor-
dance with the certified variant.
Volvo Penta accepts no responsibility or liability
for any damage or costs arising due to the above.
Introduction
21171

9
Hurth Transmission Plate
Model No. (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Ratios (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Borg Warner Transmission Plate
Model No. (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Ratio (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine - Decal
Product Designation (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product No. (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine - Plate
Product No. (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Ratio (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information
Identification Numbers
Your engine and transmission has identification plates with identification numbers. This information should always be
quoted when ordering service and replacement parts. There are probably similar plates on your boat and its equipment.
Make a note of the details below, make a copy of the page and keep it so that you have a copy should the boat be stolen.
The appearance of identification plates is shown below. The letters in brackets refer to the location of the identification
numbers on the identification plate. Note that some variation may occur in the location of numbers.
Engine decal
Hurth Transmission plate
Engine plate
Borg Warner Transmission plate
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 ownership
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.
22588

10
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
service 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 covers Volvo Penta-related repairs. Refer to the
accompanying warranty literature for detailed information
regarding coverage. Towing is not covered by the Volvo
Penta warranty. Once your warranty period has expired,
there is a charge 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.
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. The
dealer has the tools, expertise, and most current information
needed to properly perform these tasks.
“Dealer-only” maintenance items are listed in the
Maintenance 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,
accessories, coolants, and lubricants. When replacements
are required, use only Volvo Penta genuine parts.
Purchase all Volvo Penta replacement parts, accessories,
coolants, and lubricants from an authorized Volvo Penta
dealer. The dealer 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 genuine
parts and accessories directly from the factory. Volvo Penta
does not sell to unauthorized dealers or retail customers.
General Information

11
Volvo Penta Dealer Network
Volvo Penta has a comprehensive dealer network that
offers 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 dealers 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 be prepared to provide
the product designation, serial number, product type, and
drive/gear ratios. This information is located on the engine
product plate and/or decal. You should record and save
the information in this manual for future use, should it
become necessary.
Always take your Volvo Penta product to an authorized
Volvo Penta servicing dealer for repair. Our dealers have
the knowledge, factory-trained technicians, and special
tools to take care of any necessary repairs. Ideally, take
your product back to your selling dealer — he also knows
you and your equipment.
For the name and location of your nearest Volvo Penta
dealer, consult the Yellow Pages under
Boat Dealers, or
call 1-800-522-1959.
Volvo Penta on the Internet
The URL address for Volvo Penta of the Americas is http://
www.volvopenta.com.
Warranty Information
Volvo Penta’s warranty package can be found in the
accompanying warranty booklet. Along with the warranty
information you will find other checklists and reports for
Volvo Penta products.
The Volvo Penta International Warranty may apply outside
the U.S. This warranty may contain different terms and
conditions determined by prevailing national legislation
and regulations.
Some areas may have other warranty conditions,
depending on national legislation and regulations.
Information about these conditions can be obtained from
Volvo Penta importers and dealers in those areas. Contact
your local Volvo Penta representative for a copy.
Warranty Registration Form
The Warranty Registration Form should always be filled
out and sent in by the dealer. Make sure that this has been
done, since delay of warranty claims can occur if no proof
of the delivery date can be provided.
General Information

12
Features
1. Alternator
2. Coolant Circulation Pump
3. Dipstick (Engine)
4. Water Coolant Fill (Optional)
5. Flame Arrestor
6. Fuel Filter
7. Fuel Pump
8. Fuses
9. Idler Pulley
10. Oil Filter
5.7 GiI-B / HSW630A – 5.7 GiI-C / HSW630A
5.7 GXiI-C / HSW630A – 5.7 GXiI-D / HSW630A
1
2
9
10
12
13
16
9
11. Oil Siphon Tube
12. Raw Water Drain (Engine)
13. Raw Water Pump
14. Serpentine Belt
15. Starter
16. Belt Tensioner
17. Water Drain (Manifold)
18. Heat Exchanger (Optional)
19. Transmission Fluid
20. Running Engine Raw Water Flush
14
3590874-F

13
Features
3, 11
17
6, 7
15
6
7
810 3, 11
3, 11
18
20
5
4
19
3590874-S
3590874-S

14
Features
1
2
3, 11
9
10
12
13
16
9
5.7 GiI-B / HSW630D – 5.7 GiI-C / HSW630D
5.7 GXiI-C / HSW630D – 5.7 GXiI-D / HSW630D
1. Alternator
2. Coolant Circulation Pump
3. Dipstick (Engine)
4. Water Coolant Fill (Optional)
5. Flame Arrestor
6. Fuel Filter
7. Fuel Pump
8. Fuses
9. Idler Pulley
10. Oil Filter
11. Oil Siphon Tube
12. Raw Water Drain (Engine)
13. Raw Water Pump
14. Serpentine Belt
15. Starter
16. Belt Tensioner
17. Water Drain (Manifold)
18. Heat Exchanger (Optional)
19. Transmission Fluid
20. Running Engine Raw Water Flush
14
3590875-F

15
Features
3, 11
17
6, 7
15
6
7
810 3, 11
3, 11
18
20
3, 11
5
4
3590875-S
3590875-T
19

16
Features
1
2
3, 11
9
12
13
16
9
3590873-F
1. Alternator
2. Coolant Circulation Pump
3. Dipstick (Engine)
4. Water Coolant Fill (Optional)
5. Flame Arrestor
6. Fuel Filter
7. Fuel Pump
8. Fuses
9. Idler Pulley
10. Oil Filter
11. Oil Siphon Tube
12. Raw Water Drain (Engine)
13. Raw Water Pump
14. Serpentine Belt
15. Starter
16. Belt Tensioner
17. Water Drain (Manifold)
18. Heat Exchanger (Optional)
19. Transmission Fluid
20. Running Engine Raw Water Flush
5.7 GiI-B / HSW630V – 5.7 GiI-C / HSW630V
5.7 GXiI-C / HSW630V – 5.7 GXiI-D / HSW630V
14

17
Features
3, 11
17
6, 7
15
6
7
8
10
3, 11
3, 11
4
18
20
3590873-S
5
19
3590873-T

18
Features
1
2
3, 11
9
12
13
16
9
5.7 GiI-B / BWV – 5.7 GiI-C / BWV
5.7 GXiI-C / BWV – 5.7 GXiI-D / BWV
1. Alternator
2. Coolant Circulation Pump
3. Dipstick (Engine)
4. Water Coolant Fill (Optional)
5. Flame Arrestor
6. Fuel Filter
7. Fuel Pump
8. Fuses
9. Idler Pulley
10. Oil Filter
11. Oil Siphon Tube
12. Raw Water Drain (Engine)
13. Raw Water Pump
14. Serpentine Belt
15. Starter
16. Belt Tensioner
17. Water Drain (Manifold)
18. Heat Exchanger (Optional)
19. Transmission Fluid
20. Running Engine Raw Water Flush
14
3590877-F