Volvo 5.0OSiE-J User manual

OPERATOR’S MANUAL
5.0L, 5.7L, 8.1L
SX-A, DPS-A, XDP-B

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Copyright © 2007 Volvo Penta of the Americas, Inc. All rights reserved. This publication may not be copied, photocopied, re-
produced, or converted to any electronic or machine-readable form in whole or in part without the express written consent from
Volvo Penta of the Americas, Inc.
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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, lu-
bricants, fuels, and other fluids used in engines–including any waste created through the wear-
ing 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.

This manual applies to the following engines and sterndrives.
Raw Water Cooled
Model Spec. No. Drive
5.0L
5.0GXiE-J 3869446 SX-A
DPS-A
5.0OSiE-J 3869451 XDP-B
5.7L
5.7GiE300-J
5.7GXiE-J
3869447
3869448
SX-A
DPS-A
5.7OSiE300-J
5.7OSXiE-J
3869452
3869453 XDP-B
8.1L
8.1GiE-J
8.1GXiE-J
3869449
3869450 DPS-A
8.1OSiE-J 3869454 XDP-B
Closed Cooling System
Model Spec. No. Drive
5.0L 5.0GXiE-JF 3869431 SX-A
DPS-A
5.0OSiE-JF 3869432 XDP-B
5.7L
5.7GiE300-JF
5.7GXiE-JF
3869433
3869435
SX-A
DPS-A
5.7OSiE300-JF
5.7OSXiE-JF
3869434
3869436 XDP-B
8.1L
8.1GiE-JF
8.1GXiE-JF
3869437
3869439 DPS-A
8.1OSiE-JF 3869438 XDP-B

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Notes

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 beginning,
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 embracing 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.
21169

CONTACT INFORMATION
Consumer Affairs Department
Volvo Penta of the Americas, Inc.
1300 Volvo Penta Drive
Chesapeake, Virginia 23320, USA
Phone: [phone] • Fax: [phone]
http://www.volvopenta.com
Volvo Action Service - North America
P.O. Box 26113
Greensboro, North Carolina 27402-6113
Toll Free: (877) 33-PENTA • Phone: [phone]
http://myactionservice.com/English/VAS_Penta.asp
World-wide Dealer Locator
http://www.volvopenta.com

Table of Contents
VPA 7748131 English 09-2007 1
Safety Information 5
General Information ..................................................5
Safety Precautions (Maintenance and Service)........6
Knowledge ................................................................... 6
Engine Decals .............................................................. 6
Stop the Engine............................................................ 6
Lifting the Engine ......................................................... 6
Before Starting the Engine........................................... 6
Washing the Engine..................................................... 6
Fire and Explosion ....................................................... 7
Fuel and Lubrication Oil ......................................... 7
Non-Original Components...................................... 7
Batteries ................................................................. 7
Start Spray ............................................................. 7
Hot Surfaces and Fluids............................................... 8
Cooling System ............................................................ 8
Fuel System ................................................................. 8
Lubrication System....................................................... 8
Electrical System.......................................................... 8
Carbon Monoxide Poisoning ........................................ 8
Chemicals .................................................................... 8
Safety Precautions While Operating the Boat...........9
Your New Boat............................................................. 9
Accidents...................................................................... 9
Maneuvering ................................................................ 9
Emergency Stop Switch............................................... 9
Daily Checklist.............................................................. 9
Refueling...................................................................... 9
Do not Start the Engine................................................ 9
“Station Wagon” Effect & Carbon Monoxide ...........10
Safety Checklists.....................................................11
Planning Your Trip ..................................................... 11
Trip Checklist........................................................ 11
Safety Equipment....................................................... 11
Safety Equipment Checklist ................................. 11
Replacement Parts and Tools Checklist .................... 11
Basic Safety Rules of Boating.................................12
High Performance Boat Operation............................. 12
Introduction 13
Care of the Environment .........................................13
Fuel and Oils...........................................................13
Breaking-in..............................................................13
Certified Engines.....................................................14
Power Ratings.........................................................15
Load Condition (Speed of Planing Hull)..................... 15
General Information 17
Warranty Information...............................................17
Warranty Registration Form....................................... 17
Doing Your Own Maintenance and Repairs............... 17
Volvo Action Service (VAS)........................................ 17
Volvo Penta Dealer Network...................................... 17
Toll-free Dealer Locator Service........................... 17
Volvo Penta on the Internet........................................ 17
Informational Decals and Identification Plates ........18
Identification Numbers ............................................... 19
Owner’s Identification Card........................................ 20
Service, Replacement Parts, and Accessories .......20
Instrumentation 21
Instrument Panel .................................................... 21
Audible Alarm .............................................................22
Emergency Stop Switch..............................................22
Checking Instruments.................................................23
Oil Pressure ..........................................................23
Engine Coolant Temperature................................23
Voltage/Charge .....................................................23
Power Trim/Tilt............................................................24
Trim Instruments.........................................................24
Analog Trim Instrument.........................................24
Trim/Tilt Motor Protection ...........................................25
Impact Protection ..................................................25
Engine Protection Mode......................................... 26
Engine Control Module (ECM)....................................26
Other Instruments .................................................. 26
Controls 27
Remote Control Unit............................................... 27
Single Lever Control Operation ..................................27
Shifting from Neutral .............................................27
Disengaging the Shift Function .............................27
Twin Unit Maneuvering...............................................28
Neutral Interlock Button ..............................................28
Shifting between Forward and Reverse......................29
Cruising Speed ...........................................................30
How to Shift and Control Speed .................................30
Trim Controls ..............................................................31
Operating Trim Controls .............................................31
Control Panel ........................................................31
Remote Control Lever...........................................31
Friction Brake..............................................................32
Side Mount Remote Controls................................32
Top Mount Remote Controls.................................32
Operation 33
Operating the Engine ............................................. 33
Before Starting............................................................33
Starting the Engine .....................................................34
If the Engine Floods....................................................35
Stopping the Engine ...................................................35
Steering System Operation .................................... 36
Twin Unit Steering ......................................................36
Power Trim and Tilt Operation ............................... 37
Power Trim Operation.................................................37
Determining the Proper Trim ......................................38
Operating in “Bow-up” Position .............................38
Operating in “Bow-down” Position.........................39
Power Tilt Operation...................................................39
Power Trim/Tilt Switch & Gauge Location.............39
Special Boating Situations ..................................... 40
Shallow Water Operation............................................40
High Altitude Operation...............................................40
Operating in Freezing Temperatures..........................41
Salt Water Operation ..................................................41
Trailering Your Boat....................................................41
Table of Contents

Table of Contents
2VPA 7748131 English 09-2007
Features 43
Circuit Breakers and Fuses.................................... 43
Fuse and Relay Box Layout........................................43
Legend of Symbols Used in Engine Photos ...............43
5.0GXiE-J(F), 5.0OSiE-J(F), 5.7GiE300-J(F),
5.7GXiE-J(F), 5.7OSiE300-J(F),
5.7OSXiE-J(F) .............................. 44
8.1GiE-J(F), 8.1GXiE-J(F), 8.1OSiE-J(F)............... 46
SX-A Sterndrive ..................................................... 48
DPS-A Sterndrive................................................... 49
XDP-B Sterndrive................................................... 50
Maintenance Parts List 51
Engine Parts & Accessories................................... 51
Engine Parts & Accessories (Continued) ............... 52
SX-A/DPS-A Drive Parts & Accessories ................ 53
XDP-B Drive Parts & Accessories.......................... 54
Maintenance 55
Engine Break-in Period .......................................... 55
Break-in Procedures ...................................................55
First Two Hours.....................................................56
Next Eight Hours...................................................56
For the Next Ten Hours.........................................57
First Service Inspection (Dealer 50-Hour Check) .......57
Operating After Break-in Period..................................57
Preparing for Boating (Launching)..............................58
Off-Season Storage (Winterization)............................58
Static Water Line.................................................... 59
Static Water Line Test ................................................59
Maintenance Schedule........................................... 60
Maintenance of Boat’s Systems............................. 63
Engine Exhaust System ......................................... 63
Drive Unit Bellows.......................................................64
PCV Valve ..................................................................65
Checking the PCV Valve.......................................65
Fuel System ........................................................... 66
Gasoline Recommendations.......................................66
Gasoline Containing Alcohol.................................67
Leaded Fuels ........................................................67
Electronic Fuel Injection..............................................68
Detonation (Spark Knock)...........................................68
Preventing Gum Formation and Corrosion .................68
Flame Arrestor ............................................................69
Electric Fuel Pumps....................................................69
Fuel Filter....................................................................70
Engine Fuel Filter Replacement............................70
Electrical System.................................................... 71
Battery Cables ............................................................71
Batteries and Connections..........................................71
Battery Replacement ..................................................73
Multiple Batteries and Selector Switch..................73
Distributor Cap and Rotor...........................................73
Spark Plugs ................................................................74
Checking and Changing Spark Plugs ...................74
Circuit Breakers and Fuses ........................................75
Belt Replacement................................................... 76
Serpentine Belt Engines .............................................76
Cooling System ...................................................... 77
Raw Water System.....................................................77
Closed Cooling System (F-Series)............................. 77
Engine Overheating.................................................... 78
Replacing the Engine Thermostat.............................. 78
5.0–5.7L Engines (Raw Water Cooled) ................78
5.0–5.7L Engines (Closed Cooling System)......... 79
8.1 Liter Engines (Raw Water Cooled) ................. 79
8.1 Liter Engines (Closed Cooling System) .......... 80
Engine Flush .............................................................. 80
Draining the Cooling System...................................... 81
Raw Water Cooled Engines..................................81
Draining the Closed Cooling System.......................... 82
5.0–5.7 Liter Engines (F-Series)........................... 82
8.1 Liter Engines (F-Series).................................. 83
Impeller: Checking & Replacing ................................. 83
Lubrication System................................................. 84
Engine/Crankcase Oil................................................. 84
Checking Engine Oil Level.................................... 85
Changing Engine Oil.............................................85
Changing the Oil Filter..........................................86
Shaft Spline and Bearing Lubrication.........................86
Tie Rod (Twin Installations Only) ............................... 86
Steering System ......................................................... 87
Power Steering Reservoir Fluid Level ..................87
Power Trim/Tilt-Fluid: SX-A/DPS-A............................ 88
Power Trim/Tilt Fluid: XDP-B ..................................... 88
Drive Components (SX-A/DPS-A).......................... 89
Drive Unit Lubrication (SX-A/DPS-A) ......................... 89
Checking the Drive Unit Lubricant (SX-A/DPS-A) 89
Draining and Filling the Drive Unit (SX-A/DPS-A) 89
Alternate Fill Procedure (SX-A/DPS-A) ................ 91
Sterndrive Oil Capacity (SX-A/DPS-A) ................. 92
Pitot Tube (Speedometer Port) .................................. 92
Drive Components (XDP-B) ................................... 93
Drive Unit Lubrication (XDP-B)................................... 93
Checking the Drive Unit Lubricant (XDP-B).......... 93
Draining the Drive Unit (XDP-B) ........................... 93
Filling the Drive Unit (XDP-B) ...............................94
Sacrificial Anodes................................................... 95
Replacing Anodes (SX-A/DPS-A) ..............................95
Replacing Anodes (XDP-B)........................................ 96
Replacing Heat Exchanger Anodes ........................... 96
Active Corrosion Protection System
(SX-A/DPS-A Only)....................... 97
Painting the Drive (SX-A/DPS-A Only)................. 100
Preparation............................................................... 100
Paint Application (SX-A/DPS-A Only) ......................100
Painting the Drive (XDP-B Only) .......................... 101
Preparation............................................................... 101
Paint Application (XDP-B Only)................................101
Propeller Care ...................................................... 102
Propeller Replacement — SX-A...............................102
Removing the SX-A Propeller............................. 102
Installing the SX-A Propeller............................... 102
Propeller Replacement — DPS-A ............................103
Removing the DPS-A Propeller .......................... 103
Installing the DPS-A Propeller ............................103
Propeller Replacement — XDP-B ............................104
Removing the XDP-B Propeller .......................... 104
Installing the XDP-B Propeller ............................ 104

Table of Contents
VPA 7748131 English 09-2007 3
Boat Bottom ..........................................................105
Bottom Painting........................................................ 105
Engine Alignment..................................................105
Engine Submersion.................................................. 105
Replacement Parts................................................106
Troubleshooting 107
Troubleshooting - System Isolation.......................107
Engine Troubleshooting Guides............................108
Technical Data 115
Metric Conversion Chart 121
General Torque Specifications 122
Appendix – EVCEC User’s Guide 123
Features................................................................123
Main EVC Components............................................ 123
Stations .................................................................... 124
Main Station ....................................................... 125
Secondary Station (Fly Bridge Station) .............. 125
Instrumentation .....................................................126
Start/Stop Panel ....................................................... 126
Power Trim Control Panel ........................................ 126
EVC Control Panel................................................... 127
EVC Displays ........................................................... 128
EVC Basic Window ............................................ 128
Alarm Display (Optional) .......................................... 129
General Warning: Red or Amber Indicator......... 129
Oil Pressure: Red Indicator ................................ 129
Water in Fuel ...................................................... 130
Battery: Amber Indicator..................................... 130
Coolant Temperature: Red Indicator .................. 130
Coolant Level ..................................................... 130
Oil Level ............................................................. 130
Gauges (Optional).................................................... 131
Main Menu ............................................................... 132
Menu Structure................................................... 132
Trip Menu ................................................................. 134
Gauges Menu........................................................... 135
Multiple Window Display .......................................... 136
Display Contrast ................................................. 136
Connection Fault ................................................ 136
ENGINE Page (Button 1) ................................... 137
MULTI Page (Button 2) ...................................... 138
Trip Page (Button 3) ........................................... 139
Graph Page (Button 4) ....................................... 139
Operation ..............................................................140
Checking the Control Panel LEDs............................ 140
Checking the Display(s) ........................................... 140
Acknowledging Alarms and Messages............... 140
Clear Flood Before Starting the Engine.............. 140
Starting Using the Start/Stop Panel.................... 140
Operation (Continued)
Station Handling .......................................................141
Active Station ......................................................141
Changing and Activating Station.........................141
Locking/Unlocking Stations.................................142
Disengaging the Shift Function ...........................142
Engine Synchronization Function........................142
Stopping Using the Start/Stop Panel...................142
Power Trim ...............................................................143
Power Trim Buttons.............................................143
Trim Ranges........................................................144
Power Trim Instrument and Displays ..................145
Power Trim Assistant ..........................................146
Emergency Trimming..........................................146
Troubleshooting ................................................... 147
Diagnostic Function ..................................................147
Alarms and Messages ..............................................147
Alarm for Faults...................................................147
Alarm for Fuel or Depth (Optional)......................148
Acknowledging Alarms and Messages ...............149
Retrieving Faults.......................................................150
Fault Register ...........................................................151
Calibrations and Settings ..................................... 154
EVC Settings ............................................................154
Entering the Settings Menu.................................154
Contents of the Settings Menu .................................155
PTA (On/Off).............................................. 156
Neutral Beep .......................................................156
Depth Alarm (Optional) .......................................157
Units..........................................................................159
US or Metric ........................................................159
Distance ..............................................................159
Fuel Tank Calibration................................................160
Fuel Multipoint Calibration...................................160
Fuel Full Tank Calibration ...................................161
Approximated Trip Data ......................................161
Fuel Alarm Pop-up ..............................................161
Fuel Level Signal Loss........................................161
Select Language.......................................................162
Display Contrast .......................................................162
PTA Calibration.........................................................163
Speed Factor (Optional) ...........................................164
Information Beep ......................................................164
Settings – EVC System Display................................165
Display Contrast..................................................165
Configuration Menu.............................................165
Bleep...................................................................165
Engine.................................................................166
Display (Interval) .................................................166
Index 167

Table of Contents
4VPA 7748131 English 09-2007
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Notes

VPA 7748131 English 09-2007 5
Safety Information
Read this chapter carefully. It concerns your safety. This section describes how safety information is presented in
the operator’s manual and on the engine. It also gives a general account of basic safety precautions to be taken
when operating the boat and maintaining the engine.
Check that you have the correct operator’s manual before you read on. If this is not the case please contact
your Volvo Penta dealer.
This symbol is used in the book and on the engine to make you aware of safety information. Always read
these safety precautions very carefully.
Incorrectly performed operations could result in personal injury, damage to property, or harm the engine.
Read the operator’s manual carefully before operating or servicing the engine. If anything is unclear, please
contact your Volvo Penta dealer for assistance.
In the operator’s manual warning texts have the following priority:
DANGER! Failure to comply with a danger symbol will result in death.
WARNING! Failure to comply with a warning may result in serious injury.
CAUTION! Failure to comply with a caution may result in injury.
NOTICE! Special attention should be used to prevent incorrect assembly, disassembly, or use. Failure to
comply with a notice may result in equipment failure or damage.
General Information
This 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 model identification, preventive
maintenance recommendations, fuel and oil recommendations, and other important points. Please keep this book
with your boat at all times.
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 demonstrate the operation.
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
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!
Safety Information

Safety Information
6VPA 7748131 English 09-2007
Safety Precautions (Maintenance and Service)
The following sections summarize the risks associated with carrying out certain activities while operating or
maintaining your boat and engine and the safety precautions you should always observe while engaged in these
activities.
Knowledge
The operator’s manual contains instructions on how to
carry out general maintenance and service operations
safely and correctly. Read the instructions carefully
before starting work.
Service literature covering more complicated opera-
tions is available from your Volvo Penta dealer. Never
carry out any work on the engine if you are unsure
of how it should be done, contact your Volvo Penta
dealer.
Engine Decals
Check that the warning or information decals on the
engine are always clearly visible. Replace decals that
have been damaged or painted over.
Stop the Engine
Stop the engine before opening or removing engine
hatches. Unless otherwise specified all maintenance
and service must be carried out with the engine
stopped.
To prevent accidental start of the engine, remove the
ignition key, turn off the power supply to the engine at
the main switches, and lock them in the OFF position,
or disconnect the battery cables from the battery be-
fore starting work. Put up a warning sign in the control
position that work on the engine is being carried out.
Approaching or working on an engine that is running
is dangerous. Loose clothing, hair, fingers or a
dropped tool can be caught in the rotating parts of the
engine and cause serious personal injury. We recom-
mend that all servicing with the engine running be un-
dertaken by an authorized Volvo Penta workshop.
Lifting the Engine
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
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.
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. Never carry out work on an engine suspend-
ed on a hoist.
Before Starting the Engine
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.). Check that no tools or other items have
been left on the engine.
DANGER! To prevent a possible explosion
hazard, operate the engine compartment/
bilge 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 be-
fore starting so as to disperse any gasoline
fumes that may be present. Leave the hatch
open until after the engine is running.
Washing the Engine
Never use a high-pressure washer when washing the
engine.

VPA 7748131 English 09-2007 7
Safety Information
Fire and Explosion
Fuel and Lubrication Oil
All fuels, most lubricants, and many chemicals are
flammable. Read and follow the instructions on the
packaging.
When carrying out work on the fuel system make sure
the engine is cold. A fuel spill onto a hot surface or
electrical components can cause a fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire. Fuel
soaked rags can self-ignite under certain conditions.
Do not smoke when filling fuel, oil, or while in the prox-
imity of a filling station or in the engine room.
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.
Non-Original Components
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 explosion on
board. Damage caused by using non-original Volvo
Penta replacement parts will not be covered under
any warranty provided by Volvo Penta.
Batteries
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 ex-
plosive gas. This gas is easily ignited and highly vola-
tile.
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 en-
gine (spark risk) and do not lean over batteries.
Always ensure that the positive and negative battery
leads are correctly installed on the corresponding ter-
minal posts. Incorrect installation can result in serious
damage to electrical equipment.
Always use protective goggles or a face mask when
charging and handling batteries. Battery electrolyte
contains sulphuric acid, which is highly corrosive. If
battery electrolyte comes into contact with unprotect-
ed skin, wash it off immediately 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 assistance.
Start Spray
Never use start spray or similar agents to start an en-
gine. This may cause an explosion in the inlet mani-
fold.

Safety Information
8VPA 7748131 English 09-2007
Hot Surfaces and Fluids
There is always a risk of burns when working with a
hot engine. Beware of hot surfaces. For example: the
exhaust pipe and manifold, oil pan, starter element,
hot coolant, and hot oil in oil lines and hoses.
Always turn off the engine before starting service pro-
cedures. Avoid hot surfaces and liquids in supply lines
and hoses when the engine has just been turned off
and is still hot.
Cooling System
There is a risk of flooding when working on the sea-
water system. Turn off the engine and close the sea
cock (where installed) before starting work on the sys-
tem.
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.
If opening the filler cap or drain/venting cock, or re-
moving a plug or engine coolant line from a hot en-
gine, open the filler cap slowly and release coolant
system pressure gradually; otherwise, steam or hot
coolant can spray out. Note that the coolant may still
be hot and can cause burns.
Fuel System
Always use protective gloves when tracing leaks. Liq-
uids ejected under pressure can penetrate body tis-
sue and cause serious injury. There is also a danger
of blood poisoning.
Always cover the alternator if it is located under the
fuel filter. The alternator can be damaged by spilled fu-
el.
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.
Lubrication System
Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on it. Never start or
operate the engine with the oil filler cap removed; hot
oil could spray out.
Electrical System
Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block heat-
er, battery charger, or accessories mounted on the en-
gine.
Carbon Monoxide Poisoning
Only start the engine in a well-ventilated area. If oper-
ating the engine in an enclosed space, ensure that
there is proper ventilation in order to remove exhaust
gases and crankcase ventilation emissions from the
working area. Please see ““Station Wagon” Effect &
Carbon Monoxide” on page 10 for additional informa-
tion.
Chemicals
Most chemicals such as anti-freeze, rust-proofing
agents, inhibiting oils, degreasing agents, etc., are
hazardous to your health. Read and follow the instruc-
tions on the packaging.
Some chemicals such as inhibiting oil are flammable
and toxic if breathed. Ensure good ventilation and use
a protective mask when spraying.
Read and follow the instructions on the packaging.
Store chemicals and other hazardous materials out of
the reach of children. To protect the environment
please dispose of used or leftover chemicals at a
properly designated disposal site for destruction.

VPA 7748131 English 09-2007 9
Safety Information
Safety Precautions While Operating the Boat
Your New Boat
Read the operator’s manuals and other information
supplied with your new boat. Learn to operate the en-
gine, controls and other equipment safely and correct-
ly. If this is your first boat, or is a boat type with which
you are not familiar, we recommend that you practice
controlling the boat in peace and quiet, away from oth-
er vessels, docks, shallow areas, and other obstacles.
Learn how the boat behaves at different speeds, in
varying weather conditions, and alternating loads be-
fore casting off for your “real” maiden voyage.
Remember that the person driving a boat is legally re-
quired to know and follow the current rules regarding
traffic and safety at sea. Make sure you know the rules
that apply to you and the waters you are sailing in by
contacting the relevant authorities or organization. A
good piece of advice is to take a course in seaman-
ship. We recommend that you contact your local boat-
ing organization to find a suitable course.
Accidents
Statistics show that poor maintenance of boats and
engines and a lack of safety equipment are often the
main causes of accidents at sea. Ensure that your
boat is maintained in accordance with the relevant us-
er’s documentation and that the necessary safety
equipment is on-board and is serviceable.
Maneuvering
Avoid violent and unexpected changes in course and
gear engagement. This could cause someone on the
boat to lose their balance and fall over or overboard. A
rotating propeller can cause serious injury. Check that
nobody is in the water before engaging ahead or
astern. Never drive near bathers or in areas where
people could be in the water. Avoid trimming an out-
board drive too much, as steering will be severely re-
duced.
Emergency Stop Switch
We recommend that you install and use an emergen-
cy stop switch (accessory), especially if your boat can
travel at high speeds. The emergency stop switch acts
as a safety breaker and stops the engine if the driver
falls down and loses control over the boat.
NOTICE! When testing the emergency stop switch,
do so at engine idle speed only. Activating
the emergency stop switch at any speed
above idle will allow water to be ingested
into the engine, causing serious damage.
Daily Checklist
To prevent a possible explosion or fire, make a habit of
checking the engine and engine compartment visually
before operating the boat (before the engine is start-
ed) and after operating the boat (after the engine has
been stopped). Also, smell for the presence of gas
fumes. This will help you to quickly detect fuel, cool-
ant, or oil leaks and to spot anything else unusual that
has occurred or is about to happen.
If the engine compartment is not equipped with a
blower, open the engine cover or hatch before starting
it to disperse any gasoline fumes that may be present.
Leave the hatch open until after the engine is running.
Refueling
When refueling there is always a danger of fire and ex-
plosion. Smoking is forbidden and the engine must be
switched off. Never overfill the tank. Close the fuel
tank filler cap properly.
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.
Do not Start the Engine
Do not start or run the engine with a suspected fuel or
LPG leak in the boat, nor when you are close to or in
a discharge of explosive media, etc. There is risk of
fire and/or explosion in explosive surroundings.

Safety Information
10 VPA 7748131 English 09-2007
“Station Wagon” Effect & Carbon Monoxide
When a boat is moving forward, it will cause a certain
vacuum to form behind the boat. In unfortunate cir-
cumstances, the suction from this vacuum—called
“station wagon” effect—can be so great that the ex-
haust gases from the boat are drawn into the cockpit
or cabin, causing carbon monoxide poisoning.
This problem is most prevalent on boats with sheer,
broad transoms and high superstructures. In certain
conditions, however, this suction can be a problem on
other boats (e.g., when running with the cover up).
Other factors that can increase the effect of the suc-
tion are wind conditions, load distribution, swells, trim,
open hatches and portholes, and so on.
Most modern boats, however, are designed in such a
way that this problem is very rare. If suction should
arise anyway, open forward hatches or portholes. Try
changing speed, trim, or load distribution instead. Try
disassembling, opening, or in any other way changing
the setup of the cover as well.
If you suspect that your boat exhibits this “station wag-
on” effect, please contact your Volvo Penta dealer for
help in achieving the best solution for your boat.
DANGER! Do not run the engine while
there are people located on or near the swim
platform and transom.
DANGER! DO NOT tow anyone using wa-
ter sports equipment (such as skis and in-
ner tubes) closer than twenty feet (20’) from
the boat. DO NOT, under any circumstanc-
es, allow people to “body surf” using the
swim platform as a means of being pulled
along.
Travelling at slow or idle speeds may cause carbon
monoxide to accumulate in and around the boat, es-
pecially if there is a tailwind.
Carbon monoxide accumulation is particularly likely
when running the engine while docked. Be sure to
minimize the amount of time spent at the dock while
the engine is running.
For your safety, we recommend that you install a
good quality carbon monoxide detector aboard
your boat, in accordance with ABYC recommend-
ed practices.
22770

VPA 7748131 English 09-2007 11
Safety Information
Safety Checklists
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 equip-
ment and the general maintenance of the boat.
Trip Checklist
Get up-to-date charts for the planned route.
Calculate distances and fuel consumption.
Note places where you can refuel along your planned course.
Listen to the weather reports.
Tell friends or relatives about your route (that is, file a “float plan”). Remember to inform them if
your plans have changed or been delayed.
Safety Equipment
The following list of recommended safety equipment can be expanded or modified as necessary be-
cause safety equipment and other requirements vary depending on the type of boat and how it is used.
Safety Equipment Checklist
Life jackets for all passengers.
Communication equipment.
Emergency rockets or flare gun.
Approved fire extinguisher, checked and charged.
First-aid equipment.
Life belt.
Anchor, paddles, flares, and so on.
Tell your passengers and crew where the safety equipment is stored and how to operate it.
Make sure you are not the only person on board who knows how to start the boat and operate
it safely.
Replacement Parts and Tools Checklist
Extra propeller & prop hardware, impeller, fuel filters, fuses, tape, hose clamps, thermostat &
gaskets, cap & rotor, start pump & fuel pump relays, and engine oil.
Tools for any possible repairs while underway.

Safety Information
12 VPA 7748131 English 09-2007
Basic Safety Rules of Boating
We recommend that you contact your local boating or-
ganization for more detailed information on safety
afloat.
• 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.
• Prevent explosion and fire by maintaining your fuel
delivery system in top condition. Fuel vapor is vol-
atile; 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 under-
water 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 en-
gine(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 opera-
tor 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 perform-
ance with due consideration and care!
When operating at high speeds, remember that other
boaters may not realize the speed at which you are
travelling, 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 pre-
pared 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 travelling 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 whatever reason.
When driving, make sure that all passengers are safe-
ly seated. Emphasize this especially if you have a larg-
er, 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 emergency stop
switch! The emergency stop 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 over-
board 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 ap-
proximately 325 feet (100 meters) before dropping
through the planing threshold and stopping!

VPA 7748131 English 09-2007 13
Introduction
This operator’s manual has been compiled to help you get the most from your Volvo Penta engine. It contains
information you need in order to operate and maintain your engine safely and correctly. Please read the operator’s
manual carefully and learn how to operate the engine, controls, and any other equipment safely.
Always have the operator’s manual available. Keep it in a safe place and do not forget to give it to the new owner
if you sell your boat.
Care of the Environment
We would all like to live in a clean and healthy environ-
ment—somewhere where we can breathe clean air,
see healthy trees, have clean water in our lakes and
oceans, and are able to enjoy the sunshine without
being worried about our health. Unfortunately, this
cannot be taken for granted nowadays; we must work
together to achieve this vision.
As a manufacturer of marine engines, Volvo Penta
has a special responsibility, where care of the environ-
ment is a core value in our product development. To-
day, Volvo Penta has a broad range of engines on
which progress has been made in reducing exhaust
emissions, fuel consumption, engine noise, and other
detrimental side-effects. We hope you will take care in
preserving these qualities.
Always follow any advice given in the manual—con-
cerning fuel grades, operation, and maintenance pro-
cedures—and you will avoid unnecessarily harming
the environment. Get in touch with your Volvo Penta
dealer if you notice any changes such as increased
fuel consumption or exhaust smoke.
Adapt speed and distance to avoid wash and noise
disturbing or injuring animal life, moored boats, jetties,
etc. Leave islands and harbours in the same condition
as you want to find them.
Remember to always leave hazardous waste such as
waste oil, coolant, paint and wash residue, flat batter-
ies, and other toxic disposables at a suitable disposal
site or destruction plant.
Our joint efforts will make an invaluable contribu-
tion to our environment.
Fuel and Oils
Only use the fuel and oils recommended in the chap-
ter entitled Technical Data on page 115. Other grades
of fuel and oil can cause operating problems, in-
creased fuel consumption and—in the long-term—a
shorter engine service life.
Always change oil, oil filters, and fuel filters at the rec-
ommended intervals.
Breaking-in
The engine must be broken-in for its first 20 operating
hours as follows:
•Operate the engine normally.
•Do not operate it at full load except for short peri-
ods.
•Never run the engine at a constant engine speed
for long periods during the breaking-in period.
•Check the oil level more often than is normally
recommended; the engine can be expected to
use more engine oil during the breaking-in
period than would otherwise be normal.
For a more detailed explanation of the break-in period,
please refer to the appropriate section in the chapter
entitled Maintenance on page 55.
A First Service Inspection should be carried out after
50 running hours. For additional information please
refer to the document entitled Warranty Information
North America PN 7796733.
Introduction

Introduction
14 VPA 7748131 English 09-2007
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 recom-
mended by Volvo Penta must be observed.
•Only genuine Volvo Penta replacement parts
may be used.
•The servicing of ignition, timing, and fuel injec-
tion 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 person-
nel.
Otherwise the general instructions contained in this
Operator’s Manual concerning operation, service, and
maintenance must be followed.
NOTICE! Late or inadequate maintenance/service or
the use of spare parts other than Volvo
Penta original spare parts will invalidate
Volvo Penta’s responsibility for the engine
specification being in accordance with the
certified variant.
Volvo Penta accepts no responsibility or liability for
any damage or costs arising due to the above.
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