Volvo Penta 5.7 GiI-E User manual

OPERATOR’S MANUAL
5.7 GiI-E, 5.7 GXiI-F
8.1 GiI-F, 8.1 GXiI-E

CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust, some of its constituents, and a broad range of engine parts are known to
the State of California to cause cancer, birth defects, and other reproductive harm.
Additionally, lubricants, fuels, and other fluids used in engines–including any waste created
through the wearing of engine parts–contain or produce chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm.
Battery posts, terminals, and related accessories contain lead and lead compounds.Wash
your hands after handling. Used engine oil contains chemicals that have caused cancer in
laboratory animals. Always protect your skin by washing thoroughly with soap and water.

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 CoreValues:
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 demon-
strates 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
Afteruse .........................................................39
StoppingtheEngine.....................................39
SafetyMeasures..........................................39
SaltWaterOperation ....................................40
ColdWeatherPrecautions ............................40
Laying-upinWater........................................40
Laying-upon Land........................................40
MaintenanceSchedule ...................................41
Maintenance and Care ..................................42
Engine ............................................................42
Belt Adjustment ...........................................42
OilLevel:CheckingandTopping-up ..............43
OilandOilFilters:Replacement...................43
Cooling System..............................................44
DrainingCoolingSystem
(Raw Water System)........................44
DrainingThe Cooling System
(Optional Closed Cooling System)...45
Impeller:Checking& Replacing....................45
CoolingSystem:Inhibiting............................46
Fuel System....................................................47
Fuel:General ...............................................47
FuelCell ......................................................48
FuelInjection ...............................................48
FlameArrestor .............................................48
FuelFilter:Replacement ..............................49
PreventingGumFormation andCorrosion....49
ElectronicEngineControl.............................50
Ignition System ..............................................50
Spark Plugs .................................................50
IgnitionCablesand Distributor Cap ..............50
Electrical Systems .........................................51
Electrolytic Corrosion ...................................52
SacrificialAndodes ......................................52
MainON/OFFPowerSwitch ........................53
Battery:Maintenance ...................................53
Connecting andDisconnecting .....................53
Cleaning.......................................................54
Electrolyte Level ..........................................54
Battery:Charging .........................................54
Engine Alignment ..........................................55
Laying-up & Launching ................................56
Inhibiting ......................................................56
Laying-up .....................................................56
Launching ....................................................57
Paintingthedriveand underwaterhull ..........58
General ........................................................58
UnderwaterHull............................................58
EngineFlush................................................58
Troubleshooting .............................................59
Technical Data ................................................60
Fuel Specification. .......................................62
SafetyPrecautions .......................................... 3
Introduction ..................................................... 5
PowerRatings ............................................... 5
How Load Conditions Affect the Speed of a
Planing Hull...................................... 5
“Stationwagon”Effect.................................... 6
YourNew boat ............................................... 6
Boater’sResponsibilities ............................... 6
PlanningYourTrip .......................................... 6
SafetyEquipment ......................................... 7
Basic Safety Rules of Boating ...................... 7
HighPerformance BoatOperation ................. 7
CertifiedEngines .......................................... 8
General Information ........................................ 9
IdentificationNumbers .................................. 9
Owner’sIdentification Card............................ 9
Volvo Action Service (VAS) .........................10
DoingYourOwn MaintenanceandRepairs ...10
Parts and Accessories.................................10
ConsumerAffairs Department......................10
VolvoPentaDealerNetwork .........................11
Volvo Penta on the Internet ..........................11
WarrantyInformation ....................................11
WarrantyRegistrationForm..........................11
Features .........................................................12
Transmissions ...............................................26
Instrumentation .............................................28
Tachometer ..................................................28
TemperatureGauge ......................................28
OilpressureGauge ......................................28
Voltmeter .....................................................28
InstrumentLighting ......................................28
Fuses, 8 Amp ..............................................29
Ignition Switch .............................................29
Emergency Stop Switch...............................30
Controls ..........................................................31
Maneuvering ................................................31
DisengagingtheShiftFunction ....................31
Adjustment of Friction Brake ........................32
Starting the Engine ........................................33
Preparations.................................................33
Starting........................................................34
If Engine Floods...........................................34
Operation........................................................35
CheckingInstruments ..................................35
OilPressure.................................................35
EngineCoolantTemperature.........................35
Charge .........................................................35
Engine ProtectionMode ...............................36
Master/SlaveInstallation..............................36
HighAltitudeOperation ................................36
HowtoShiftandControlSpeed ...................37
TwinUnitManeuvering .................................37
CruisingSpeed.............................................38

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
recommendations, fuel and oil recommendations,
and other important points. Please keep this book
with your boat at all times.
NOTE! It is important that this manual stays with
the boat when it is sold. Important safety
information must be passed to the new
owner.The service 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 demon-
strate the operation.
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 authorizedVolvo 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
operator, 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 precau-
tions you should always observe or carry out when
operating or servicing the engine:
Safety Precautions
1. Check that the warning or information decals on
the engine are always clearly visible. Replace
decals that have been damaged or painted over.
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 manufac-
turer 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
hazardous to health and to the environment.
Whenever you use these agents, follow the
manufacturer’s instructions on the product
packaging.
12. Certain engine oils are flammable. Some of them
are also dangerous if inhaled. Whenever you use
these agents, follow the manufacturer’s instruc-
tions 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 connec-
tions 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 corre-
sponding terminal posts. Incorrect installation can
result in serious damage to electrical equipment.
16. Always use protective goggles when charging and
handling batteries. Battery electrolyte contains sulfu-
ric acid, which is highly corrosive. If battery electro-
lyte comes into contact with unprotected skin, wash it
off immediately using plenty of water and soap. If bat-
tery acid comes in contact with the eyes, immediately
flush with an abundant amount of water and obtain
medical assistance.
17. To ensure safe handling and to avoid damaging en-
gine components on top of the engine, use a lifting
beamto raise theengine.All chainsandcables should
run parallel to each other and as perpendicular as
possible in relation to the top of the engine. Always
check that lifting equipment is in good condition and
has sufficient load capacity to lift the engine and any
extra equipment installed.
18. If extra equipment is installed on the engine, which
alters its center of gravity, a special lifting device is
required to achieve the correct balance for safe han-
dling.
19. Never work on an engine that is suspended on a
hoist.
20. Components in the electrical, ignition, and fuel sys-
tems on Volvo Penta products are designed and con-
structed 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 ex-
plosion on board. Damage caused by using non-
original Volvo Penta replacement parts will not be
covered under any warranty provided byVolvo 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 gen-
erator can be damaged by spilled fuel.
22. Always use protective gloves when tracing leaks. Liq-
uids ejected under pressure can penetrate body tis-
sue 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
barometric 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 manufac-
turers 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 deter-
mining the rating of the engine.
Condition Value
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 combustion.
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
remembering 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
“Stationwagon” 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
“Stationwagon effect.” Due to a difference in air pres-
sure, 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 concen-
trations these fumes may be hazardous. If you suspect
that your boat exhibits this “Stationwagon” effect. Please
contact your Volvo Penta dealer.
WARNING!
Do not run the engine while there are people
located on or near the swim platform and
transom.
DANGER!
DO NOT tow anyone using water sports equip-
ment (such as skis and inner tubes) closer than
ten feet (10’) from the boat. DO NOT, under any
circumstances,allow people to“body surf”
using the swim platform as a means of being
pulledalong.
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 familiar-
ize 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
Maintenance Schedule. ) The owner/operator must keep
records of all maintenance services performed. This
record of proper maintenance may be required to
determine warranty coverage on certain repairs and
should be transferred to each subsequent owner. If you
are not sure of the proper maintenance procedures,
contact the Volvo Penta Consumer Affairs Department 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
equipment and explain how to use it. Be sure one of
your passengers knows how to handle your boat in
case of emergency.
Requirements for personal flotation devices (life vests,
life preservers) and other safety equipment vary,
depending on the type of boat and local regulations.
Always comply with the regulations that apply to your
boat.
PlanningYourTrip
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.
Get up-to-date charts for the planned route.
Calculate distance and fuel consumption.
Note places where you can refuel along your
planned course.
Tell friends or relatives about your route (that is,
file a “float plan”).
21170

7
Introduction
Safety Equipment
Rescue and emergency items such personal
flotation devices and signal rockets. Make sure all
passengers know where these items are.
Replacement parts.
Proper tools.
Fire extinguisher checked and charged.
Basic Safety Rules of Boating
• Shut off the engine when people who are in the
water come near the boat.
• Propellers are inherently dangerous and, as such,
are potential safety hazards. Make sure that the
propeller is not operating when people who are in
the water come near the boat.
• Avoid standing up or shifting weight suddenly in
small, lightweight boats.
• Keep your passengers seated in seats.The boat’s
bow, gunwale, transom, and seat backs are not
intended for use as seats.
• Insist on the use of personal flotation devices by all
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 OPERATETHE BOAT IFYOU ARE UNDER
THE INFLUENCE OF DRUGS OR ALCOHOL.
• If boating in waters that are unfamiliar, obtain
appropriate charts to avoid damage from underwa-
ter 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 dis-
tance 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 condi-
tions.
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 hap-
pen. 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 whatever 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 consider-
ably, 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
approximately 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 manufac-
turer 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 recom-
mended 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 autho-
rized 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 invalidateVolvo
Penta’s responsibility for the engine specifi-
cation being in accordance with the certified
variant.
Volvo Penta accepts no responsibility or
liability for any damage or costs arising due
to the above.
Introduction
21171