Volvo 5.7GiE300-J, 5.7GXiE-J, 5.7OSXiE-J, 8.1GiE-J, 8.1GXiE-J Operator's Manual

OPERATOR’S MANUAL

5.0L, 5.7L, 8.1L

SX-A, DPS-A, XDP-B

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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, 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.

Copyright © 2007 Volvo Penta of the Americas, Inc. All rights reserved. This publication may not be copied, photocopied, reproduced, 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.

This manual applies to the following engines and sterndrives.

Raw Water Cooled

Model Spec. No. Drive

5.0L

5.7L

8.1L

5.0L

5.0GXiE-J 3869446

5.0OSiE-J 3869451 XDP-B

5.7GiE300-J

5.7GXiE-J

5.7OSiE300-J

5.7OSXiE-J

8.1GiE-J

8.1GXiE-J

8.1OSiE-J 3869454 XDP-B

3869447 3869448

3869452 3869453

3869449 3869450

SX-A

DPS-A

SX-A

DPS-A

XDP-B

DPS-A

Closed Cooling System

Model Spec. No. Drive

5.0GXiE-JF 3869431

5.0OSiE-JF 3869432 XDP-B

SX-A

DPS-A

5.7L

8.1L

5.7GiE300-JF

5.7GXiE-JF

5.7OSiE300-JF

5.7OSXiE-JF

8.1GiE-JF

8.1GXiE-JF

8.1OSiE-JF 3869438 XDP-B

3869433 3869435

3869434 3869436

3869437 3869439

SX-A

DPS-A

XDP-B

DPS-A

Notes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21169

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.

CONTACT INFORMATION

Consumer Affairs Department

Volvo Penta of the Americas, Inc. 1300 Volvo Penta Drive Chesapeake, Virginia 23320, USA Phone: (757) 436-5100 • Fax: (757) 436-5153 http://www.volvopenta.com

Volvo Action Service - North America

P.O. Box 26113 Greensboro, North Carolina 27402-6113 Toll Free: (877) 33-PENTA • Phone: (336) 393-4966 http://myactionservice.com/English/VAS_Penta.asp

World-wide Dealer Locator

http://www.volvopenta.com

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:

Safety Information

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!

VPA 7748131 English 09-2007 5

Safety Information

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 operations 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 before 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 recommend that all servicing with the engine running be undertaken by an authorized Volvo Penta workshop.

Lifting the Engine

To ensure safe handling and to avoid damaging engine 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 alters its center of gravity, a special lifting device is required to achieve the correct balance for safe handling. Never carry out work on an engine suspended 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 before 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.

6 VPA 7748131 English 09-2007

Fire and Explosion

Safety Information

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 proximity 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 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 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 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.

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.

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 unprotected 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 engine. This may cause an explosion in the inlet manifold.

VPA 7748131 English 09-2007 7

Safety Information

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 procedures. 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 seawater system. Turn off the engine and close the sea cock (where installed) before starting work on the system.

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 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. Note that the coolant may still be hot and can cause burns.

Fuel System

Always use protective gloves when tracing leaks. Liquids ejected under pressure can penetrate body tissue 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 fuel.

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 heater, battery charger, or accessories mounted on the engine.

Carbon Monoxide Poisoning

Only start the engine in a well-ventilated area. If operating 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 information.

Chemicals

Most chemicals such as anti-freeze, rust-proofing agents, inhibiting oils, degreasing agents, etc., are hazardous to your health. Read and follow the instructions 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.

8 VPA 7748131 English 09-2007

Safety Precautions While Operating the Boat

Safety Information

Your New Boat

Read the operator’s manuals and other information supplied with your new boat. Learn to operate the engine, controls and other equipment safely and correctly. 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 other vessels, docks, shallow areas, and other obstacles. Learn how the boat behaves at different speeds, in varying weather conditions, and alternating loads before casting off for your “real” maiden voyage.

Remember that the person driving a boat is legally required 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 seamanship. We recommend that you contact your local boating 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 user’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 outboard drive too much, as steering will be severely reduced.

Emergency Stop Switch

We recommend that you install and use an emergency 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 started) 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, coolant, 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 explosion. 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.

VPA 7748131 English 09-2007 9

Safety Information

“Station Wagon” Effect & Carbon Monoxide

When a boat is moving forward, it will cause a certain vacuum to form behind the boat. In unfortunate circumstances, the suction from this vacuum—called “station wagon” effect—can be so great that the exhaust 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 suction 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 wagon” 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 water sports equipment (such as skis and inner tubes) closer than twenty feet (20’) from the boat. DO NOT, under any circumstances, 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, especially 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 recommended practices.

22770

10 VPA 7748131 English 09-2007

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 equipment 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 because 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.

VPA 7748131 English 09-2007 11

Safety Information

Basic Safety Rules of Boating

We recommend that you contact your local boating organization 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 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 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 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 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 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 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 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!

12 VPA 7748131 English 09-2007

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.

Introduction

Care of the Environment

We would all like to live in a clean and healthy environment—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 environment is a core value in our product development. Today, 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—concerning fuel grades, operation, and maintenance procedures—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 batteries, and other toxic disposables at a suitable disposal site or destruction plant.

Our joint efforts will make an invaluable contribution to our environment.

Fuel and Oils

Only use the fuel and oils recommended in the chapter entitled Technical Data on page 115. Other grades of fuel and oil can cause operating problems, increased fuel consumption and—in the long-term—a shorter engine service life.

Always change oil, oil filters, and fuel filters at the recommended 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 Infor mation North America PN 7796733.

VPA 7748131 English 09-2007 13

Introduction

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.

22771

14 VPA 7748131 English 09-2007

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 manufacturers 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

Air temperature .........................25°C (77°F)

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).

Load Condition (Speed of 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 semi-planing 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 water line–a problem that is often overlooked.

VPA 7748131 English 09-2007 15

Introduction

Notes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 VPA 7748131 English 09-2007

General Information

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.

Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and instructions contained in the document entitled Warran- ty Information North America PN 7796733.

Note that Volvo Penta’s liability is limited to that contained in Warranty Information North America. Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service, and maintenance which you must be aware of, check, and carry out. Liability covered in the warranty may otherwise be refused by Volvo Penta.

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. Information about these conditions can be obtained from Volvo Penta importers and dealers in those areas. Please 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.

Please contact your Volvo Penta dealer if you have not received a copy of Warranty Information North America PN 7796733 and a customer copy of the warranty card.

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 which 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.

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.

If you have a question about Volvo Action Service, or need additional information, please call toll-free 1877-33-PENTA.

Volvo Penta Dealer Network

The Volvo Penta worldwide network of authorized dealers are at your service. They are specialists in Volvo Penta products and have the accessories, original replacement parts, test equipment, and special tools necessary for high quality service and repair work.

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.

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. For the name and location of your nearest Volvo Penta dealer, consult the Yellow Pages under Boat Dealers, search the dealer locator on the internet, 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.

VPA 7748131 English 09-2007 17

General Information

Informational Decals and Identification Plates

The following images provide graphical representations of various engine decals. The areas described are general locations and are intended to be guides only. Engine models and configurations do vary and, depending on the amount of space available, the exact locations of engine decals tend to vary also.

22772

22774

3863274

22773

The engine decal is located on the engine cover.

The engine plate is typically located on the port side of the engine flywheel housing, slightly below and aft of the exhaust manifold.

The label depicting the serpentine belt configuration is typically mounted on a flat surface located on the front of the alternator/automatic tensioner bracket.

The California Emission sticker is located on the engine cover.

The Emission Control Information sticker is located on

22776

the flat outside face (port side of engine) of the alternator support bracket.

22775

18 VPA 7748131 English 09-2007

The tune-up and color code decal is located on the engine cover.

General Information

Identification Numbers

Always provide the engine, transom shield, and drive identification numbers when ordering service or replacement components. The engine identification numbers are on informational decals located in the spots described on the previous page. Make a note of the information on the lines provided below. Make a copy of this page and store the information so that it is available in event of the boat being stolen.

Engine - Decal

Product Designation (A) ..............................................................

Specification No. (B) ...................................................................

Serial No. (C) ..............................................................................

Engine - Plate

Product No. (A) ...........................................................................

Type (B) .......................................................................................

Serial No. (C) ..............................................................................

Transom Shield Plate

Product No. (A) ...........................................................................

Type (B) .......................................................................................

Ratio (C) ......................................................................................

Serial No. (D) ..............................................................................

Drive

Product No. (A) ...........................................................................

Type (B) .......................................................................................

Ratio (C) ......................................................................................

22772

22774

22778

Serial No. (D) ..............................................................................

22778

Transom Assembly & Drive Unit Stickers

22779

Product Designation (A) .................................... /...................................

Specification No. (B) .................................. /..........................................

Serial No. (C) .......................................... /............................................

22780

The Transom Assembly & Drive Unit Stickers shown above should be located on the Engine Decal. Your Volvo Penta dealer will have attached these stickers at the time that the transom assembly and drive unit were mounted on your boat and attached to the engine.

VPA 7748131 English 09-2007 19

General Information

Owner’s Identification Card

When you purchased your boat the dealer was required to register your power package with Volvo Penta. Your dealer should provide you with proof of ownership in the form of an Owner's Registration Card or a print-out of the Volvo Penta computer on-line registration screen. This provides proof of ownership and is required to validate warranty, should warranty service become necessary. Warranty coverage may be delayed until the warranty and registration form is on file at Volvo Penta.

Service, Replacement 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. Also, Volvo Penta marine engines are designed for high operational reliability and a long service life. They are manufactured to withstand the marine environment while also affecting it as little as possible. Through regular service and the use of Volvo Penta original spare parts, these qualities will be retained.

When replacements are required, use only Volvo Penta genuine parts. Always follow the maintenance intervals contained in the operator’s manual. Remember to state the engine/transmission identification number when ordering service and replacement 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.

20 VPA 7748131 English 09-2007

Instrumentation

Instrument Panel

The following section contains a general description of the instrument panel. Please note that instrument panels are installed by the boat builder and will vary depending on the model installed. Commonly, instrument panels are equipped with a tachometer, temperature gauge, oil pressure gauge, voltmeter, instrument panel lighting switch, and an ignition switch.

Instruments and ignition switches can also be supplemented with extra Volvo Penta instruments such as: synchronization tachometers, fuel gauge, fresh water gauge, clock, speed log, or rudder indicator.

Note that the instrument cluster which is shown here installed in the instrument panels can be installed in other positions on some boats. If your boat is fitted with instruments not described here and you are not sure of their function, please get in touch with your boat dealer.

NOTICE! The instrument panel depicted below is a

sample representation only.

21179

1. Tachometer—Shows the engine RPM rate. Multiply this value by 100 or 1000 (depending on model) for revolutions per minute. Integral “Hours run” meter (optional and separately installed) displays the engine’s operating time in hours and tenths of an hour.

2. Temperature Gauge—Indicates engine temperature. Normal operating temperature for all 5.0–5.7L engines is 155°-178°F (68°-81°C) and 135°-158°F (57°-70°C) for 8.1L engines. Engines with closed cooling systems will typically run about 30°F (17°C) higher.

3. Oil Pressure Gauge—Indicates the engine oil pressure. Normal operating oil pressure should be approximately 18 psi (124 kPa) minimum at 2000 RPM on a warm engine. Lower oil pressure is normal and should be expected at idle after a sustained cruise.

4. Voltmeter—Indicates the charge voltage from the alternator which should normally be approximately 14 Volts. With the engine stopped and the switch on, battery voltage is normally indicated as 12 Volts.

5. Instrument Lighting—On Volvo Penta instrument panels, turns panel lights on or off (varies, depending on product manufacturer).

6. Ignition Switch—The ignition switch has three positions (varies, depending on product manufacturer):

0 The key can be inserted or removed.

I RUN: Ignition is ON and engine is OFF. System

voltage connected.

II START position (momentary). The starter mo-

tor is engaged and starting the engine.

NOTICE! Read the starting instructions in the section

21181

The ignition keys are marked with a code for use when ordering extra keys (varies, depending on product manufacturer). Record the code so that replacement keys can be ordered. Keep the code in a safe place where unauthorized persons do not have access to it.

VPA 7748131 English 09-2007 21

entitled Starting the Engine on page 34.

Instrumentation

Audible Alarm

If an audible alarm1 has been installed on your boat, it will perform a brief self-test when the ignition key is turned to the RUN position. Following is a description of how the alarm performs the self test.

EFI Engines - When the ignition switch is turned to RUN (key on, engine off), the alarm emits three short beeps to indicate that the ECM is performing a check of the sensors. If there are any problems detected by the ECM, the alarm will sound; otherwise, it will remain off.

Emergency Stop Switch

An emergency stop switch, also called a safety breaker, may be a feature of your boat. Use of this switch is highly recommended. To properly use this feature, attach the lanyard to clothing that will NOT tear away before the lanyard is pulled from the switch to stop the engine. If the lanyard is too long, shorten it by knotting or looping it. DO NOT cut and re-tie the lanyard.

21182

The emergency stop switch can only be effective when in good working order. Observe the following:

• Lanyard must always be free of entanglements

that could hinder its operation.

• Once a month, check the switch for proper oper-

ation. With engine running at idle speed, pull lanyard. If engine does not stop, see your dealer for repairs.

Using this switch is simple and should not interfere with normal operation of the boat. Care must be tak-

en to avoid accidentally pulling the lanyard during boat operation. Unexpected loss of forward motion will occur, as well as possible damage to the engine. This could cause occupants to be thrown for-

ward. In an emergency situation, any occupant of the boat may attempt to restart the engine by pressing in and holding the emergency stop switch button, followed by normal starting procedures. When the button is released, the engine will stop.

If your boat is not equipped with an emergency stop switch and it falls into one of the following categories, installation of an emergency stop switch is recommended.

• High performance sport boats

• Small runabouts

• Boats with sensitive steering

• Boats where the distance from the top of the

gunwale down to the driver’s seat is less than one foot (30 cm).

Contact your Volvo Penta dealer for installation of an emergency stop switch.

1. While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an audible alarm available, we strongly recommend that you contact your dealer to have one installed.

22 VPA 7748131 English 09-2007

51274c

Instrumentation

Checking Instruments

Check instruments regularly. Stop the engine if there is an abnormal reading or if the engine alarm sounds.

Oil Pressure

All engines have what is considered a normal operating oil pressure range. At engine idle this is normally lower than at higher RPMs. For the normal operating oil pressure range for your model engine, please refer to the section entitled Technical Data on page 115.

Your boat is equipped with an audible low oil pressure

1

alarm

.

NOTICE! If oil pressure is too low: Stop the engine

immediately and investigate. Operating the engine with oil pressure too low will damage the engine.

Engine Coolant Temperature

All engines have what is considered a normal operating temperature range. At engine idle this is normally lower than at higher RPMs. Normal operating temperature for all 5.0–5.7L engines is 155°-178°F (68°-81°C) and 135°-158°F (57°-70°C) for 8.1L engines. Engines with closed cooling systems will typically run about 30°F (17°C) higher.

51274d

51274e

Your engine is equipped with an engine coolant and exhaust temperature acoustic alarm

1

.

NOTICE! If engine coolant or exhaust temperature is

too high: Idle the engine, shift to reverse and then to forward. Idle the engine for 2 to 3 minutes and shut off the engine if the temperature does not decrease. Investigate and correct the malfunction. Operating an engine with temperatures too high will damage the engine.

Voltage/Charge

The operating charge is approximately 14 V. When the engine is stopped and ignition is on, battery voltage is approximately 12 V. With the ignition turned off, the voltmeter will not register a charge.

1. While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your

boat does not have an audible alarm available, we strongly recommend that you contact your dealer to have one installed.

VPA 7748131 English 09-2007 23

Instrumentation

Power Trim/Tilt

Your Volvo Penta sterndrive is equipped with a power trim/tilt system as standard equipment. The power trim/tilt allows you to change the angle of the drive unit from the helm. Changing the angle of the drive unit in relation to the boat bottom is called trimming. Trimming provides these benefits:

• Improves acceleration to planing.

• Keeps the boat on plane at reduced throttle set-

tings.

• Improves fuel economy.

• Provides smoother and/or drier ride in choppy

water conditions.

• Increases maximum speed.

If you do not wish to use this feature, you may leave the drive unit trimmed to the position that works best for you.

22781

22782

Trim Instruments

The trim instrument indicates the current trim position. Your boat may be equipped with an analog or a digital trim instrument.

Analog Trim Instrument

The analog trim instrument has three main ranges:

• Trim Range–Use trim range for maximum com-

fort, under normal operation, from start to maximum speed.

• Beach Range–Use beach range for operating at

reduced speed in shallow water, where water depth is uncertain. Also use this range when you launch and take your boat out of water onto a trailer ramp.

• Lift Range–Use lift range for lifting the drive to

its maximum angle; however, this range cannot be used during boat operation. Use this range

ONLY when you are transporting your boat.

CAUTION! Operating in beach range or lift range will cause significant loss of maneuverability.

NOTICE! The maximum safe engine speed in the

Beach Range is 1000 RPMs. Operating in beach range above idle speed, or for prolonged periods of time, may cause serious drive damage. Always check that the cooling water intake is below the surface of the water when running in Beach Range.

22783

24 VPA 7748131 English 09-2007

Instrumentation

Trim/Tilt Motor Protection

NOTICE! Always allow the trim/tilt switch to return to its center position when the drive unit reaches its maximum

raised or lowered position. This precaution will prevent your trim/tilt motor from overheating.

Impact Protection

The trim/tilt system provides impact protection in the trim/tilt cylinders. If an impact occurs while in forward motion, the cylinders will allow the drive to “kick up,” thereby helping to minimize drive damage. However, impact damage can occur in either FORWARD or REVERSE directions.

NOTICE! When backing-up in REVERSE, there is no impact protection. Be very careful when backing-up in RE-

VERSE. Do not exceed 2500 RPM.

You must be careful when:

• You operate in FORWARD or REVERSE.

• You are backing up.

• You trailer your boat.

• You launch your boat.

NOTICE! Impact damage is more likely to occur when

you are in a turn where side loads are placed on the drive unit.

50406

If you strike a solid object:

• Throttle back and shut off the engine immedi-

ately.

• Closely inspect the boat and drive unit (espe-

cially the transom shield assembly that contains steering system components).

• Check the engine compartment for water leak-

age.

If there is damage, operate the boat at low RPM and take it to a Volvo Penta dealer for inspection. Operating a damaged unit could cause additional damage and could become very costly to repair. Have necessary repairs made immediately. Only operate your boat if absolutely necessary.

NOTICE! Always check your boat and engine for

damage. Failure to inspect for damage may:

• Result in sudden loss of steering control.

• Adversely affect your boat’s capability to resist

high-speed impacts.

22392

VPA 7748131 English 09-2007 25

Instrumentation

Engine Protection Mode

In a low oil pressure, low voltage, engine overheat, or lack of exhaust cooling water situation, the Electronic Fuel Injection (EFI) system will enter an Engine Protection Mode (EPM). In such cases, if an acoustic alarm has been installed with your engine, the alarm will sound to notify you of a malfunction.

Under these conditions, engine operation is limited to 2500 RPMs or less. When the engine enters EPM, there will be a temporary reduction in power until the problem is resolved. We strongly urge you to bring the engine to idle to investigate the problem. If the acoustic alarm stops sounding, the malfunction has been cleared and the engine may now be operated normally.

If you are unable to locate and resolve the problem, you may continue to operate the engine at above idle speed, keeping in mind that the acoustic alarm will continue sounding and the engine speed will remain below 2500 RPMs

NOTICE! Continuing to run the engine in engine pro-

tection mode without correcting the cause may result in engine damage.

1

.

51279c

CAUTION! If a malfunction triggers the engine protection mode, the engine may either return to idle or shut down, depending on the engine equipment and circumstances.

Use the oil pressure and water temperature gauges to verify a problem exists, then inspect the engine crankcase for proper oil level and check the water inlets for obstructions. The low oil pressure/engine overheat problem must be corrected before the engine will return to normal operation.

To reset the Engine Protection Mode after the problem is corrected, reduce engine speed to idle, allow the engine to cool, and then continue with normal operation.

NOTICE! If the problem continues, contact your Vol-

vo Penta dealer and have the engine inspected.

Engine Control Module (ECM)

The engine control module (ECM) is designed to maintain exhaust emission levels while maintaining excellent drivability and fuel efficiency. The ECM controls the following conditions:

• Fuel, ignition, and idle air control.

• Knock sensor system.

• Various other discrete outputs.

Other Instruments

See your Volvo Penta dealer for additional accessories specifically designed for your Volvo Penta product.

1. In boats equipped with the Electronic Vessel Control system (EVC-ec), alarm handling is different. After the alarm is acknowledged, the buzzer is turned off. Please refer to the appendix for additional information.

26 VPA 7748131 English 09-2007

Controls

Remote Control Unit

Volvo Penta controls are available in single top-mount, twin top-mount, or single side-mount configurations. The control levers have an adjustable friction brake and a neutral position switch to ensure that the engine cannot be started when the drive is in gear.

Your boat may be equipped with remote controls other than those described below. If Volvo Penta controls are not used, ask your dealer for operating instructions for the remote control used in your boat since operation and function may differ from Volvo Penta remote controls.

Single Lever Control Operation

Both the gear shift release and engine speed control are operated using the single lever (1).

N Neutral position (drive is disengaged and the

engine runs at idle speed).

F Drive/forward gear engaged for forward move-

ment (ahead).

R Drive/reverse gear engaged for backward

movement (astern).

T Throttle/engine speed control.

NOTICE! The engine can be started only if the drive

is in neutral.

51260

Shifting from Neutral

To move the remote control lever from the neutral detent position, simply move the control lever in the desired direction.

Disengaging the Shift Function

The gear shift can be disengaged so that the control lever affects only the engine speed.

1. Move the control lever 2 to the neutral position N.

2. On the EVC control panel, press the NEUTRAL BUTTON 9 in and hold it down while moving the control lever forward to the shift position F.

3. Release the NEUTRAL BUTTON. The lever now affects only the engine speed (RPMs). The Neutral button LED flashes when in neutral warm-up mode. When the lever is moved back to neutral, gear shifting will function normally.

51264

VPA 7748131 English 09-2007 27

Controls

Twin Unit Maneuvering

When leaving or approaching the dock, or for any close maneuvering at slow speed, place the port engine control lever 3 in neutral N (on standby) and use the starboard engine. The use of one control is very effective and more convenient. In the event that the starboard engine (which is being used for maneuvering) stops, you can immediately go to the port engine (which has been on standby).

NOTICE! Both engines must be running during close

maneuvering or at slow speeds. If only one engine is running, water may be forced back through the underwater exhaust outlet and cause serious engine damage. Do not attempt to plane boat while operating on a single engine; operating with a single engine at full throttle could cause engine or transmission damage.

51259

51266a

Neutral Interlock Button

The neutral interlock button 1, available on the sidemount control only, prevents accidentally moving the throttle out of neutral. This button must be depressed to shift the throttle out of neutral.

To move the control lever away from neutral:

1. With the control handle in NEUTRAL, depress the neutral interlock button 1.

2. While keeping the button pressed, move control handle out of neutral in the desired direction. Once the throttle is out of the neutral position, you may release the button.

The neutral interlock will automatically re-engage when the control handle is returned to the NEUTRAL position.

28 VPA 7748131 English 09-2007

Controls

Shifting between Forward and Reverse

• To go from forward to reverse, or reverse to for-

ward, always pause at neutral N and allow engine speed to return to idle.

• After shifting is completed, continue to move the

control handle slowly in the desired direction to increase speed.

NOTICE! Do not shift gears if engine speed is above

800 RPM. Do not shift from forward to reverse when boat is planing. There is a danger that water will get into the engine and cause serious damage, while causing serious damage to the drive.

CAUTION! Any time the boat is operated, be aware of changes in shift system operation. A sudden increase in shift effort at the remote control handle, or other abnormal operation, indicates a possible problem in the shift system. If you suspect there is a problem, see your Volvo Penta dealer as soon as possible for proper diagnosis and required service or adjustment. Continued operation could result in damage to the shift mechanism and loss of shift and throttle control that could result in personal injury.

51260

VPA 7748131 English 09-2007 29

Controls

Engine WOT Range (RPM)

5.0 GXiE-J(F) 4600–5000

5.0 OSiE-J(F) 4600–5000

5.7 GiE300-J(F) 4600–5000

5.7 GXiE-J(F) 4800–5200

5.7 OSiE300-J(F) 4600–5000

5.7 OSXiE-J(F) 4800–5200

8.1 GiE-J(F) 4200–4600

8.1 GXiE-J(F) 4600–5000

8.1 OSiE-J(F) 4200–4600

Cruising Speed

Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed 25% lower than maximum RPM at WOT. Depending on hull type, choice of propeller, load and conditions, etc., the maximum engine speed at top speed can vary, but it should be within the WOT range.

How to Shift and Control Speed

If your boat is equipped with a non-Volvo Penta remote control system, ask your dealer how to properly operate it.

51260

NOTICE! Verify proper functionality of all control and

engine systems before leaving the dock.

1. Move control handle(s) to the neutral detent position N. Check in front and behind boat for people or obstructions before shifting.

2. To go forward: Move the control handle forward from neutral detent to forward gear engagement detent position F. Throttle movement will begin after the detent position for forward gear engagement. After the throttle is activated, continue to move the control handle slowly in the desired direction to increase speed.

3. To go in reverse: Move the control handle backward until you reach the detent position for reverse gear engagement R. Throttle movement will begin after reverse gear engagement. After the throttle is activated, continue to move the control handle slowly in the desired direction to increase speed.

NOTICE! Do not shift gears if engine speed is above

800 RPM.

30 VPA 7748131 English 09-2007

16783

Controls

Trim Controls

Trimming (raising and lowering the drive) can be performed by using:

• A separate control panel (shown at left) on the

instrument panel.

• A control button 2 on the single control lever.

• The control buttons 4 & 5 on the port control

lever in a twin installation.

The current trim position is indicated on a trim gauge located on the instrument panel, in the tachometer LCD display, or elsewhere on the dashboard.

Operating Trim Controls

Control Panel

The control panel has two standard buttons for tilt control:

51266

• The top button moves the drive trim out while

raising the boat’s bow.

• The lower button moves the drive trim in while

lowering the boat’s bow.

Remote Control Lever

The control button on the control lever has two functions:

• Pressing the top half of the button moves the

drive trim out while raising the boat’s bow.

• Pressing the bottom half of the button moves the

drive trim in while lowering the boat’s bow.

51267

VPA 7748131 English 09-2007 31

Controls

Friction Brake

The remote control has a friction brake, which can be adjusted as necessary, to provide lighter or heavier lever action. If you are using a Volvo Penta shift control and you wish to make adjustments to the friction brake, follow the instructions below to make the necessary changes.

NOTICE! Each manufacturer has a particular method for making adjustments to the friction brake. For specific

directions on how to adjust a non-Volvo Penta friction brake, please refer to your manufacturer’s manual.

NOTICE! The brake must only be adjusted when the control lever is in the throttle range. Do not adjust the friction

with the control in neutral.

Side Mount Remote Controls

1. Make sure the engine is turned off by removing the key from the ignition switch.

2. Remove the plastic cover that shields the remote control mechanism.

3. Place the control lever in reverse (just beyond the reverse detent position) and adjust the throttle brake screw to prevent throttle creep.

51263

4. Turn the tension screw B clockwise to increase drag and counter-clockwise to decrease drag on the control arm.

5. Reinstall the plastic cover and remote control lever.

Top Mount Remote Controls

1. Make sure the engine is turned off by removing the key from the ignition switch.

2. Remove the plastic cover that shields the remote control mechanism.

3. For single lever controls, move the throttle to the forward position. For dual lever controls, move the port side lever forward and the starboard side lever into reverse.

4. Turn the tension screw A clockwise to increase drag and counter-clockwise to decrease drag on the control arm.

5. Reinstall the plastic cover and remote control lever.

51262

32 VPA 7748131 English 09-2007

Operation

Operating the Engine

NOTICE! Do not start the engine out of the water unless you have connected a hose with running water to the

flushing adapter. Please refer to the section entitled Engine Flush on page 80 for instructions on attaching and running the engine out of water.

Thoroughly familiarize yourself with the operation of the remote control supplied with your boat, then proceed as follows.

Before Starting

DANGER! To prevent a possible explosion hazard, operate the engine compartment or bilge blower as recommended by the boat

21192

21190

manufacturer before starting the engine. If the engine compartment is not equipped with a blower, open the engine cover or hatch before starting so as to disperse any gasoline fumes that may be present. Leave the hatch open until after the engine is running.

1. Start the boat’s bilge blower and run as recommended by the boat manufacturer. Frequently check boat’s bilge area for gasoline fumes.

51216

21181

2. Check the bilge for excessive water accumulation. Always keep the bilge clean and dry.

NOTICE! The water level in the boat’s bilge will in-

crease when you operate your boat at a high incline before you reach planing speed. Excessive water in the bilge can cause engine damage.

3. Open the fuel cock A. Also, ensure that the sea cock is open–if so equipped.

4. Make sure that there are no fuel, engine coolant, or oil leaks B.

5. Check engine oil level C. Level must be between D and E. Note: The oil level may be higher than D at start up.

6. If equipped, turn on the main battery switches.

7. Insert the key into the ignition switch O. Turn the key one step to the right I to switch on engine system voltage and instrumentation.

8. Make sure that the fuel gauge is operating and that you have enough gasoline F.

51274f

VPA 7748131 English 09-2007 33

Operation

9. Lower the drive unit to normal run position; make sure the water intakes are submerged. There should be no obstructions in the water near the propellers.

50404

22392-1

51260a

Starting the Engine

EVC-ec engines are equipped with an auto-crank feature. Momentarily turning the key to the start position, then releasing it back to the ON position I will cause the engine to continue to crank for up to 5 seconds or until the engine starts.

If you attempt to execute a "fast crank" (turning the key from OFF immediately all the way to START), there will be a 3–5 second delay while EVC "warms up."

1. Move the control handle to the neutral detent position N.

2. Turn the ignition switch to START II. If the engine does not start, then try again.

NOTICE! If engine cranking needs to be aborted, the

key can be turned to the OFF position 0.

NOTICE! Never leave the key in the ON position with

the engine not running.

NOTICE! If the engine floods during a warm start,

simply follow the directions provided in the section entitled If the Engine Floods on page 35 to restart the engine.

21181

34 VPA 7748131 English 09-2007

51260b

Operation

If the Engine Floods

1. Turn the key to ON or RUN I.

2. On the EVC control panel, press and hold the NEUTRAL BUTTON 9 while moving the control lever 2 forward to the shift position F.

3. Let go of the NEUTRAL BUTTON and move the remote control lever to FULL THROTTLE T.

NOTICE! Be prepared to quickly move the control

handle to IDLE once the engine starts. This will avoid over-speeding and possibly damaging the engine.

4. Turn the ignition switch to START II. If the engine does not start, then try again.

NOTICE! After a second attempt, if the engine still

does not start, return the control lever to the neutral position and try a normal engine start.

51264

21181

5. As soon as the engine starts:

• Return the remote control handle to IDLE.

• Return the key to ON or RUN I.

NOTICE! Immediately after engine start-up, look at all

instruments. If any readings are abnormal, stop the engine and determine the cause.

Stopping the Engine

1. Move the remote control lever to NEUTRAL N.

2. Let engine return to idle.

3. Turn ignition key to OFF 0.

NOTICE! Do not stop the engine at speeds above idle

or “speed up” the engine while turning off the ignition. Do not stop the engine while in gear or while the boat is moving. Engine damage could result from water being sucked back up through the exhaust ports.

VPA 7748131 English 09-2007 35

Operation

Steering System Operation

The steering system for your Volvo Penta sterndrive is operated by a steering cable connected to the helm. Restricting movement of the steering cable will limit or stop the steering system’s hydraulic assist.

Do not interfere with or restrict steering cable movement through the last 90° of bend at the engine. Do not use cable retainers, clamps, or tie straps. Using one or all of these could restrict the cable movement near the engine. Do not tie wiring harnesses or other control cables to the steering cable. Make sure deck combing and bulkheads allow for steering cable movement.

If the power steering system stops working, it will feel harder to steer. If this condition occurs, look for possible causes and fix them if possible. If the power steering system cannot be corrected on board, proceed at a reduced speed. You will be able to steer the boat, but with increased effort. See your authorized Volvo Penta dealer as soon as possible to correct your power steering system.

At slow speeds (no wake), your boat may tend to wander. This is normal and may be overcome by anticipating bow direction and correcting with steering wheel. A slightly higher throttle and trim setting may also lessen the tendency to “wander.” Changing weight distri-

21182

bution, aft to forward, can also affect slow speed steering.

50405

Twin Unit Steering

Twin engine boats may have only one engine with a fully operational power steering system. That power steering system is on the starboard engine; therefore, when operating on a single engine use the starboard engine.

Using a port engine that does not have a functional power steering system will cause an increased effort in steering control, due to absence of power assist.

NOTICE! Both engines must be running during close

maneuvering or at slow speeds. If only one engine is running, water may be forced back through the underwater exhaust outlet and cause serious engine damage. Do not attempt to plane boat while operating on a single engine; operating with a single engine at full throttle could cause engine or transmission damage.

36 VPA 7748131 English 09-2007

Operation

Power Trim and Tilt Operation

Trimming and tilting the drive is done from a control switch mounted on the remote control (2, 4, 5) or by using the switches on the dash (shown below). When using the dash mounted switches, the bottom button lowers the bow and the top button raises the bow. The switch on the remote control lever raises and lowers the drive when its upper or lower segment is pressed.

NOTICE! Allow the trim/tilt switch to return to its cent-

er position when the drive unit reaches the maximum raised or lowered position. This will prevent your trim/tilt motor from overheating.

The trim/tilt motor is protected from overheating by an internal thermal overload switch. If the electric motor stops while tilting, release the switch and allow the overload switch to cool and automatically reset itself. When the overload switch has reset, tilting may be resumed. Make sure the drive unit is not being re-

16783

strained, causing the motor to overheat. If the electric motor still does not operate, check the 40-amp breaker located in the fuse box.

For additional information about Trim and Tilt controls, please refer to Controls on page 27 and Power Trim on page 143.

1

circuit

51266

Power Trim Operation

The power trim is normally used before you accelerate onto plane, after you reach the desired RPM or boat speed, and when there is a change in water or boating conditions. Locate passengers and equipment in the boat so that the weight is balanced fore and aft, and side to side. Trimming will not cancel an unbalanced load.

To operate the trim, push and hold the switch “bow-up” or “bow-down” until the desired bow position is reached. The trim may be operated at any boat speed or at rest. Avoid operating the trim system when running in reverse.

Observe the trim/tilt gauge, which indicates the bow position achieved. The upper scale of the trim gauge indicates the “bow-up” positions, and lower scale of the trim gauge indicates the “bow-down” positions.

For additional information, see Determining the Prop-

er Trim on page 38.

51267

VPA 7748131 English 09-2007 37

1. 50-amp on Ocean Series (OSi) engines.

Operation

16783

Determining the Proper Trim

The effect of the maximum “bow-up” and “bow-down” positions will be similar for most boats. The bow position best for your operating conditions could be at any trim setting between the maximum “bow-up” and “bow-down” positions.

The boat will be properly trimmed when the trim angle provides the best boat performance for your operating conditions. On models without power steering, the trim position that provides a balanced steering load is desirable.

To familiarize yourself with the power trim, make test runs at slower speeds and at various trim positions to see the effect of trimming. Note the time it takes for the boat to plane. Watch the tachometer and speedometer readings and the ride action of the boat.

The following sections entitled Operating in “Bow-up” Position and Operating in “Bow-down” Position provide additional information on this topic.

22796

Operating in “Bow-up” Position

The “bow-up” A position is normally used for cruising, running with a choppy wave condition, or running at full speed. In a full “bow-up” position the boat may tend to self-steer. You may have to compensate with the steering wheel to keep the boat in a straight-ahead path. In this position the boat’s bow will tend to raise clear of the water. Excessive “bow-up” trim will cause propeller ventilation resulting in propeller slippage. Engine RPM will also increase, but boat speed will not increase and may even drop.

CAUTION! Use caution when operating in rough water or crossing another boat’s wake. Excessive “bow-up” trim may result in the boat’s bow rising rapidly and possibly throwing the boat’s occupants into the water.

38 VPA 7748131 English 09-2007

22797

Operation

Operating in “Bow-down” Position

The “bow-down” B position is normally used for acceleration onto plane, operating at slow planing speeds, and running against a choppy wave condition. In the fully “bow-down” position the boat may tend to selfsteer. You may have to compensate with the steering wheel to keep the boat in a straight-ahead path. In this position the boat’s bow will tend to go deeper into the water. If the boat is operated at high speed and/or against high waves, the bow of the boat will plow into the water. The boat may tend to bow steer or spin about rapidly and possibly eject occupants.

NOTICE! The boat trim should be adjusted to provide

balanced steering as soon as possible each time you get underway. Some boat, engine, and propeller combinations may encounter boat instability and/or high steering torque when operated at or near the limits of the “bow-up” or “bow-down” positions. Boat stability and steering torque can also vary due to changing water conditions. If you experience boat instability and/or high steering torque, see your Volvo Penta dealer to correct these conditions.

Power Tilt Operation

Tilting is normally used for raising the drive unit to obtain clearance when beaching, launching from a trailer, or mooring. When tilting the drive unit, the boat should be at rest or at idle speed only.

The trim/tilt switch controls the tilting feature of the drive unit. When the trim/tilt switch is held in the “bow-up” position, the drive unit tilts up until the switch is released or the drive unit reaches the maximum tilt position.

NOTICE! Never exceed 1000 RPM when operating the drive unit in the tilted position because it may damage the

drive system. Never RUN the engine when the drive unit is tilted more than 30° or the drive will be damaged.

Never operate the engine out of water or without water supplied to the engine. The water pump may be damaged or the engine may overheat. For additional information, see Engine Flush on page 80.

WARNING! To avoid possible contact with the propellers, never use the drive unit as a ladder or as a lift to board the boat. Never board at the rear of the boat when the engine is running, even if the engine is operating in neutral. Personal injury could result from contact with rotating engine parts and propellers.

Any malfunction of the trim/tilt system could result in a loss of impact protection. Malfunction can also result in loss of reverse thrust capability. If a malfunction occurs, see your authorized Volvo Penta dealer.

Power Trim/Tilt Switch & Gauge Location

The power trim/tilt switch is located on the remote control handle or on the boat’s dashboard. The trim indicator displays the drive position in the Trim range. With dual installations, it is permissible to individually trim the drive in Trim range. When the drive is in Beach range, boat speed must be lower than planing speed. The engine must be stopped when fully tilted (Lift Range).

VPA 7748131 English 09-2007 39

Operation

Special Boating Situations

The following section covers scenarios that are considered special boating situations. When using the boat in the following situations, there are some special procedures to take into consideration in order to keep the engine, transmission, drive, and propeller in top working condition.

Shallow Water Operation

You may tilt the drive unit to reduce the draft for shallow water running A as long as you do not exceed 1000 RPM. Exceeding 1000 RPM is not necessary. It will only increase the boat wake and will not increase boat speed appreciably.

NOTICE! Exceeding 1000 RPM with the drive unit tilt-

ed could damage drive train components. This type of damage is not covered by warranty. Never attempt to plane the boat or ex-

22798

ceed 1000 rpm with the drive unit in a partially tilted position. Always return to the trim range as soon as possible to avoid damage to drive train. Never RUN the engine with the drive unit tilted more than 30° or the drive will be damaged.

When operating in shallow water, be sure the water intakes located in the lower gear unit are submerged at all times. Proceed at slow speed and lower drive unit immediately when deeper water is reached.

NOTICE! Be very careful when operating in shallow

water; the intakes may pick up mud, sand, underwater vegetation, or other submerged debris. This may lead to overheating and engine damage.

High Altitude Operation

Volvo Penta EFI engines have programmed altitude compensation; however, there may be a slight performance loss at altitudes above 5000 feet due to lower air density. If you are boating above 5000 feet for a short time, a lower pitch propeller will restore some of the lost performance. Long term use above altitudes of 5000 ft. may require a change in gear ratio which is not covered under the Volvo Penta Limited Warranty.

22799

40 VPA 7748131 English 09-2007

Operation

Operating in Freezing Temperatures

When freezing temperatures are forecast and the boat will be operated and left in the water, the drive unit must remain in the tilted down (submerged) position at all times to prevent water in the drive unit from freezing. Upon completion of engine operation, drain the engine as described in the maintenance section of this manual.

21199

22800

Salt Water Operation

You can use your Volvo Penta sterndrive in either fresh or salt water.

We recommend that you use fresh water to flush out the engine and drive as described in the maintenance section of this manual after you use it in polluted or salt water. This will prolong the service life of the manifolds and risers. For additional information, see En- gine Flush on page 80.

Trailering Your Boat

If your boat will be trailered, tilt the drive unit out of the water. After you remove your boat from the water, lower the drive unit to the RUN (down) position until the cooling system drains thoroughly.

Rinse the entire drive exterior with fresh water, then dry it and spray it with anti-corrosion spray.

Before trailering your boat on the road, check the ground clearance of the drive unit. When trailering, the drive unit may be in the up or down position. There must be at least 15 inches (38.1 cm) clearance between the lower gear unit and the ground. If the clearance is less than 15 inches (38.1 cm), raise the drive unit.

NOTICE! Be very careful when you back out of drive-

ways or cross railroad tracks, so that the sterndrive does not hit the ground.

Make sure that the boat fits the trailer properly. In many cases, loss of performance and speed is due to improper trailer support and too much tie-down pressure, which causes the boat bottom to deform. The boat should rest firmly on the trailer with maximum tiedown pressure applied at the bow and transom only.

VPA 7748131 English 09-2007 41

Operation

Notes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 VPA 7748131 English 09-2007

Features

Your Volvo Penta product consists of three components: the engine, transom shield and the sterndrive. There are certain parts on each component that you, the owner, must take care of to make sure that your Volvo Penta product stays in optimum running condition. The important parts of each component are shown in the illustrations on the following “Features” pages. Explanations of these parts and systems are described below; the maintenance procedures are found in the Maintenance section.

Features

Circuit Breakers and Fuses

Fuse and Relay Box Layout

Several spare fuses and relays are located on the inside of the fuse and relay box cover. In case of malfunctioning or faulty fuses and relays, use the spares provided.

23672

A Trim Down Relay B Trim Up Relay C Starter Relay D Fuel Pump Relay E Ignition Relay F1 15 Amp Fuse (EVC–Secondary) F2 20 Amp Fuse (EVC–Primary)

F3 20 Amp Fuse (Fuel Pump) F4 15 Amp Fuse (Ignition) F5 5 Amp Fuse (Vessel Switch) F6 20 Amp Fuse (ECM) F7 40 Amp Fuse (Instrument Panel) F8 40 Amp or 50 Amp Circuit Breaker (Trim Pump) F9 20 Amp Fuse (Starter)

Legend of Symbols Used in Engine Photos

1 2 3 4 56789

22341 22874 22343 22342 22345 22372 22873 22346 22377

1 Engine Oil 2 Engine Oil Level 3 Power Steering Fluid 4 Sterndrive Oil 5 Engine Raw Water Drain

6 Engine Coolant Drain (Closed Cooling) 7 Engine Coolant 8 Running Engine Flush 9 Heat Exchanger Raw Water Drain

1

1. Ocean Series (OSi) engines require the use of a 50 Amp fuse. All other engines require a 40 Amp fuse.

VPA 7748131 English 09-2007 43

Features

5.0GXiE-J(F), 5.0OSiE-J(F), 5.7GiE300-J(F), 5.7GXiE-J(F),

5.7OSiE300-J(F), 5.7OSXiE-J(F)

51300

1. Exhaust Risers

2. Exhaust Overheat Sensors

3. Powertrain Control Unit

4. Engine Control Unit

5. Engine Thermostat Housing

6. Flame Arrestor

7. Shift Actuator

8. Circuit Breakers, Fuses, and Relays

9. Alternator

10. Oil Dipstick

11. Oil Siphon Tube

12. Engine Oil Filter Assembly

44 VPA 7748131 English 09-2007

13. Power Steering Fluid Fill

14. Serpentine Belt

15. Power Steering Pump

16. Raw Water Pump

17. Heat Exchanger

18. Anode

19. Engine Water Circulation Pump

20. Fuel Pump (High Pressure)

21. Fuel Pump (Low Pressure)

22. Fuel Filter

23. Automatic Belt Tensioner

24. Running Engine Flush Port

25. Engine Coolant Fill

26. Spark Plugs

27. Oil Fill Cap

28. Exhaust Manifold Water Drain

29. Engine Raw Water Drain

30. Starter

31. Exhaust Manifold

32. Distributor

33. PCV Valve

1. Raw water cooled engines only

2. Not shown

2

1

Features

51301

51302

VPA 7748131 English 09-2007 45

Features

8.1GiE-J(F), 8.1GXiE-J(F), 8.1OSiE-J(F)

51303

1. Exhaust Risers

2. Exhaust Overheat Sensors

3. Engine Coolant Fill

4. Circuit Breakers, Fuses, and Relays

5. Shift Actuator

6. Flame Arrestor

7. Powertrain Control Unit

8. Alternator

9. Engine Control Unit

10. Oil Dipstick

11. Oil Siphon Tube

46 VPA 7748131 English 09-2007

12. Engine Oil Filter Assembly

13. Power Steering Fluid Fill

14. Serpentine Belt

15. Power Steering Pump

16. Engine Oil Cooler

17. Raw Water Pump

18. Engine Water Circulation Pump

19. Heat Exchanger

20. Fuel Pump (High Pressure)

21. Fuel Pump (Low Pressure)

22. Fuel Filter

23. Automatic Belt Tensioner

24. Engine Thermostat Housing

25. Running Engine Flush Port

26. Spark Plugs

27. Oil Fill Cap

28. Anode

29. Exhaust Manifold Water Drain

30. Engine Raw Water Drain

1

31. Starter

32. Exhaust Manifold

1. Raw water cooled engines only

Features

51304

51305

VPA 7748131 English 09-2007 47

Features

SX-A Sterndrive

50465

1. Oil Fill

2. Trim Sender

3. Trim Pump Oil Fill

1

4. Trim Pump

1. Trim pump oil is not a regular maintenance item. Please refer to the section entitled Power Trim/Tilt-Fluid: SX-A/DPS-A on page 88 for additional information.

48 VPA 7748131 English 09-2007

5. Anodes

6. Pitot Tube

7. Raw Water Intake

8. Oil Drain

9. Propeller

10. Trim Cylinder

DPS-A Sterndrive

Features

50397

1. Oil Fill

2. Trim Sender

3. Trim Pump Oil Fill

6. Pitot Tube

7. Raw Water Intake

1

8. Oil Drain

9. Front Propeller

10. Rear Propeller

11. Trim Cylinder

4. Trim Pump

5. Anodes

1. Trim pump oil is not a regular maintenance item. Please refer to the section entitled Power Trim/Tilt-Fluid: SX-A/DPS-A on page 88 for

additional information.

VPA 7748131 English 09-2007 49

Features

XDP-B Sterndrive

23741

1. Oil Fill

2. Trim Sender

3. Anodes

1. A third anode (not shown) is located on the trim cylinder. See Replacing Anodes (XDP-B) on page 96.

50 VPA 7748131 English 09-2007

1

4. Raw Water Intake

5. Oil Drain

6. Rear Propeller

7. Front Propeller

Engine Parts & Accessories

Maintenance Parts List

23179

5.0GXiE-J 3869446 8692305 3847302 3587597 3862228

5.0GXiE-JF 3869431 8692305 3847302 3831426 3862228

5.0OSiE-J 3869451 8692305 3847302 3587597 3862228

5.0OSiE-JF 3869432 8692305 3847302 3831426 3862228

5.7GiE300-J 3869447 8692305 3847302 3587597 3862228

5.7GiE300-JF 3869433 8692305 3847302 3831426 3862228

5.7GXiE-J 3869448 8692305 3847302 3587597 3862228

5.7GXiE-JF 3869435 8692305 3847302 3831426 3862228

5.7OSiE300-J 3869452 8692305 3847302 3587597 3862228

5.7OSiE300-JF 3869434 8692305 3847302 3831426 3862228

5.7OSXiE-J 3869453 8692305 3847302 3587597 3862228

5.7OSXiE-JF 3869436 8692305 3847302 3831426 3862228

8.1GiE-J 3869449 8692305 3847302 3853983 3862228

8.1GiE-JF 3869437 8692305 3847302 3831426 3862228

8.1GXiE-J 3869450 8692305 3847302 3853983 3862228

8.1GXiE-JF 3869439 8692305 3847302 3831426 3862228

8.1OSiE-J 3869454 8692305 3847302 3853983 3862228

8.1OSiE-JF 3869438 8692305 3847302 3831426 3862228

51218

23180

23177

23170

VPA 7748131 English 09-2007 51

Maintentance Parts List

Engine Parts & Accessories (Continued)

23185

23179

23171

23184

23172-1

5.0GXiE-J 3869446 3842786 3858996 X 2 3858977 3858975

5.0GXiE-JF 3869431 3842786 3858996 X 2 3858977 3858975

5.0OSiE-J 3869451 3842786 3858996 X 2 3858977 3858975

5.0OSiE-JF 3869432 3842786 3858996 X 2 3858977 3858975

5.7GiE300-J 3869447 3842786 3858996 X 2 3858977 3858975

5.7GiE300-JF 3869433 3842786 3858996 X 2 3858977 3858975

5.7GXiE-J 3869448 3842786 3858996 X 2 3858977 3858975

5.7GXiE-JF 3869435 3842786 3858996 X 2 3858977 3858975

5.7OSiE300-J 3869452 3842786 3858996 X 2 3858977 3858975

5.7OSiE300-JF 3869434 3842786 3858996 X 2 3858977 3858975

5.7OSXiE-J 3869453 3842786 3858996 X 2 3858977 3858975

5.7OSXiE-JF 3869436 3842786 3858996 X 2 3858977 3858975

8.1GiE-J 3869449 3842786 3861326 X 2 – –

8.1GiE-JF 3869437 3842786 3861326 X 2 – –

8.1GXiE-J 3869450 3842786 3861326 X 2 – –

8.1GXiE-JF 3869439 3842786 3861326 X 2 – –

8.1OSiE-J 3869454 3842786 3861326 X 2 – –

8.1OSiE-JF 3869438 3842786 3861326 X 2 – –

23382

23179

All Engines with Closed

Cooling Systems (F-Series)

1. Applies to factory-installed Volvo Penta closed cooling systems only. After-market kits may have different anodes installed.

3858995

1

23389

381081

52 VPA 7748131 English 09-2007

SX-A/DPS-A Drive Parts & Accessories

50388

23180

50395

3883600, 3883601,

SX-A

DPS-A

3883602, 3883603, 3883604, 3883605, 3883623, 3883599, 3883606, 3883607,

3883609, 3883610

3851128

3888817 (Zn)

3888818 (Mg)

3888816 (Al)

Maintenance Parts List

50389

3888814 (Zn)

3888815 (Mg)

3888813 (Al)

SX-A

DPS-A

50395

3883600, 3883601, 3883602, 3883603, 3883604, 3883605, 3883623, 3883599, 3883606, 3883607,

3883609, 3883610

50390

23246

3841293 3854127

VPA 7748131 English 09-2007 53

Maintentance Parts List

XDP-B Drive Parts & Accessories

XDP-B

22392-2

3869151 3869152 3869153

23180

3851128

3862048

3861634

3861634 # (Zn)

3861635 # (Mg)

3862048 (X-B, X-BLT)

3862466 (XHP-B, XHP-BLT)

3861636

3861636 # (Zn) 3861633 # (Mg)

3860419

23773-1

3861583

54 VPA 7748131 English 09-2007

Maintenance

Engine Break-in Period

NOTICE! To ensure proper lubrication during the break-in period, do not remove factory break-in oil until after the

20-hour break-in is completed. The First Service inspection should be carried out after 50 hours of operation.

NOTICE! Failure to follow engine break-in procedures can result in serious engine damage.

NOTICE! Do not run engine at a constant RPM for prolonged periods of time during the break-in period.

All Volvo Penta engines have been run for a short time during a final test at the factory. You must follow the engine break-in procedure during the first 20 hours of operation to ensure maximum performance and longest engine life.

Break-in Procedures

During the break-in period, watch out for the following items during the initial engine run:

1. Check engine oil level frequently (C) with the boat in the water. Level must be between E (add) and D (full).

NOTICE! The engine may use more engine oil during

the break-in period than would otherwise be normal. Be sure to check the oil level frequently during the first 20 hours of opera-

51216

tion, since the oil consumption will be high until the piston rings are properly seated.

• Maintain oil level in the safe range, between the

ADD and FULL marks on dipstick. Somewhat higher oil consumption is normal until the piston rings have seated.

• If you have a problem getting a good oil level

reading on the dipstick, rotate the dipstick 180° in the dipstick tube.

• When adding engine oil, use Volvo Penta engine

oils for gasoline engines, or a good quality oil (API Service CF/SH and ILSAC GF-4 grade or better) of the same viscosity. Use the following chart to select the SAE viscosity that matches the temperature range in which you expect to operate.

Lowest Anticipated

Temperatur e

32° F (0° C) — above

0° F (-18° C) — 32° F (0° C) SAE 20W-20 Below 0° F (-18° C) SAE 10W

Recommended SAE

Viscosity Oils

SAE 30 SAE 20W/50 SAE 15W/50

NOTICE! Use Volvo Penta Engine Oil, Synthetic or Mineral, recommended for 0°F (-18°C) and above. For addi-

tional information, see Maintenance Schedule on page 60.

VPA 7748131 English 09-2007 55

Maintenance

2. Watch the oil pressure gauge.

• Oil pressure will rise as RPM increases, and fall

as RPM decreases. In addition, cold oil will generally show higher oil pressure for any specific RPM than hot oil. Both of these conditions reflect normal engine operation.

• If the oil indicator fluctuates when the boat is

turning, climbing on plane, etc., the oil pickup screen may not be covered with oil. Check the oil dipstick. If required add non-synthetic oil, but do not overfill. If the oil level is correct and the condition persists, ask your Volvo Penta dealer to check for possible gauge or oil pump malfunction.

3. Watch the engine temperature indicator to be sure there is proper coolant circulation.

NOTICE! Failure to follow the break-in procedure may

void the engine warranty.

First Two Hours

1. For the first five to ten minutes of operation, run the engine at a fast idle (above 1500 RPM).

2. During the remaining first two hours of operation, accelerate to bring the boat onto plane quickly; bring the throttle back to maintain a planing attitude.

During this period, vary the engine speed frequently by accelerating to approximately ¾ throttle for two to three minutes, then back to minimum cruising speed.

3. After the engine has reached operating temperature, momentarily reduce engine speed, then increase engine speed, to assist break-in of rings and bearings. Maintain plane to avoid excessive engine load.

NOTICE! For this initial two hour break-in, do not run

the engine at any constant RPM for prolonged periods of time.

Next Eight Hours

1. During the next eight hours, continue to operate at approximately ¾ throttle or less (minimum cruising speed). Occasionally reduce throttle to idle speed for a cooling period.

22812-1

56 VPA 7748131 English 09-2007

2. During this eight hours of operation you may operate at full throttle for periods of less than two minutes.

Maintenance

For the Next Ten Hours

1. During the final ten hours of break-in, you may operate at full throttle for five to ten minutes at a time.

2. After warming the engine to operating temperature, momentarily increase engine speed.

3. Occasionally reduce engine speed to idle to provide cooling periods.

After the first 50 hours of operation, drain the engine oil and replace the oil filter. Fill the crankcase with Volvo Penta’s engine oil.

22814

First Service Inspection (Dealer 50-Hour Check)

To ensure your continued boating enjoyment, we recommend that you return your Volvo Penta product to your Volvo Penta dealer for a 50-hour check. This 50-hour check will prevent a minor problem from getting worse and helps ensure a trouble-free boating season. When servicing your engine, your Volvo Penta dealer will use the following guidelines to inspect your product:

Start the engine and check that:

• No leakage of fuel, oil, water, or exhaust gases

occurs.

• Engine oil pressure and temperature are within

specification.

• All cables and controls operate correctly.

• All gauges, instruments, and alarms operate cor-

rectly.

• Steering system operates correctly.

• Engine ignition timing and idle RPM are within

specifications.

• Power trim system operates correctly.

Stop the engine and:

• Change engine oil and oil filter.

• Change fuel/water separator filter.

• Clean seawater strainer (if equipped).

This is a perfect time to discuss with your Volvo Penta dealer any questions about your engine that may have arisen during the first 50 hours of operation and establish a routine preventive maintenance schedule.

• Check fluid levels and fluid condition in stern-

drive or inboard transmission, power steering pump, and trim pump.

• Check propeller(s) and propeller fasteners.

• Check condition of battery and battery cable

connections.

• Lubricate all grease fittings and linkages follow-

ing service recommendations.

• Check tightness of all water, fuel, exhaust

clamps, fittings, drive bellows, and drains.

Restart the engine and recheck that:

• No leakage of fuel, oil, water, or exhaust gases

occurs.

• Engine oil pressure and temperature are within

specifications.

NOTICE! Always insist that your dealer use genuine Volvo Penta parts when replacing engine components.

Operating After Break-in Period

After the break-in period, the engine can be operated at any RPM from idle to full throttle. Cruising at 3600 RPM or less, however, saves fuel, reduces noise, and prolongs engine life.

VPA 7748131 English 09-2007 57

Maintenance

Preparing for Boating (Launching)

When launching your boat for the first time or when starting out a new season, always carry out the steps provided in the following checklist:

 Replace all drain plugs.

 Replace rubber caps and clamps or plugs.

 Connect hoses and check their condition;

tighten clamps and connections.

 Install boat drain plug, if removed.

 Remove and inspect distributor cap and rotor.

Replace distributor with a new one, if necessary.

 Clean battery terminals and check battery

charge.

21201

 With ignition switch in OFF position, install

battery and attach battery cables.

 Spray terminals with Volvo Penta anti corro-

sion spray.

 Open the fuel shut-off valve and check all fuel

line connections for leaks.

 Check the flame arrestor and clean if neces-

sary (see Flame Arrestor on page 69 ).

 Make a thorough check of boat and engine for

loose or missing nuts and screws.

 Pump the bilge dry and air out engine com-

partment. Federal, state, and/or local regulations prohibit the pumping of oil into any navigable waters.

 Check all reservoir oil levels and fill as neces-

sary.

 Check drive and transom shield anodes.

Clean or replace as necessary.

Off-Season Storage (Winterization)

Be sure that your Volvo Penta equipment is properly prepared for off-season storage. Engine or drive damage can result if some simple maintenance steps are overlooked prior to storage. Winterizing gives you the assurance that your engine will be protected during storage and will run more reliably when you put your boat back in the water.

We recommend that you have your Volvo Penta dealer “winterize” your engine and drive. Your dealer will pro-

21199

58 VPA 7748131 English 09-2007

vide the proper servicing and maintenance to ensure that your equipment is treated and stored properly.

Maintenance

Static Water Line

Check the static water line if the loading or weight distribution in the rear of the boat has changed significantly from the boat manufacturers original design. This would include the addition of an auxiliary outboard on brackets, onboard generators, towers, personal water craft mounted on the rear of the boat, coolers, and bait wells, and so on.

Static Water Line Test

NOTICE! The static water line height must be tested

before the engine is started for the first time. Checking the static water line will help prevent the ingestion of water into the engine and the resultant damage.

1. Load the boat and distribute weight as you would for normal boating conditions.

2. Place a level on top of transom, measure from bottom of level to top of riser (B) and record measurement.

NOTICE! The addition of extra equipment such as a generator, auxiliary trolling motor, live wells, supplemental

fuel or water tankage, etc. may alter the water line or balance point of your boat. This may cause water to enter the exhaust, causing serious engine damage. Before making changes that affect the boat’s water line, consult your dealer to see if modifications will be required on your engine.

3. Measure from bottom of the level to static water line (A) and record measurement.

4. Subtract measurement B from measurement A and record result (C). Measurement C should not be less than 14 in. (35.6 cm).

A – B = C

5. When the static water line does not meet these specifications, contact your Volvo Penta dealer for information on high rise extension kits. Make sure one is installed before the engine is started for the first time.

50427

VPA 7748131 English 09-2007 59

Maintenance

Maintenance Schedule

The operation, maintenance, and care of the Volvo Penta engine and power package as outlined in this manual are the owner’s responsibility. The owner 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 provided in the front of this manual.

In addition to the maintenance routines outlined on these pages, we recommend that you return your Volvo

Penta product to your authorized Volvo Penta dealer for a 50-hour check. For additional information, see First Service Inspection (Dealer 50-Hour Check) on page 57.

NOTICE! All maintenance schedule frequencies listed in the following table apply to a maintenance schedule that

begins AFTER the Dealer 50-Hour Check. Do not include the 50 hours prior to the dealer 50-hour check as part of your calendar or operating hour frequency. For example, the fuel filter needs to be replaced one year or 100 operating hours (whichever comes first) following the dealer 50-hour check, not after 50 operating hours.

WARNING! To prevent fire or explosion, Volvo Penta ignition components meet U.S. Coast Guard requirements for external ignition proof parts. Do not substitute automotive or other non-approved parts.

MAINTENANCE POINT

Required Action(s) Important Notes

Belt: Serpentine

Check for wear

Cooling System

Check coolant level and check for leakage

Distributor Cap and Rotor

Clean, check to see if worn or damaged

Engine Mounting Screws

Tighten screws

Engine Oil

Check level

Engine Oil, Mineral

Replace

Engine Oil, Synthetic – Every 200 hours for Volvo Penta synthetic oil.

Replace

Engine Oil Filter

Replace with every oil change only

Exhaust Manifold, Risers

Check for corrosion, damage, and blockage

Exhaust System, Rubber Boots

Check for damage and blockage

Flame Arrestor

Check for damage/dirt and tighten mounting

Fuel Filter

Replace

Fuel Pump, Electric

Check for leaks

Fuel System, Hoses, Tank, etc.

Check for leakage or blockage

ENGINE PACKAGE

Calendar Frequency OR Operating Hours

Refer to

Page

76

77

73

105

84–85

63

69

69–70

66–70

Each

Usage

•

(WHICHEVER COMES FIRST)

Monthly

OR

Every 50

Hours

Yearly

OR

Every 100

Hours

Once Every

2 Years

Every 200

Hours

•

OR

Once Every

3 Years

OR

Every 300

Hours

60 VPA 7748131 English 09-2007

ENGINE PACKAGE (CONTINUED)

Maintenance

MAINTENANCE POINT

Required Action(s) Important Notes

Impeller, Raw Water Pump

Replace

PCV Valve

Check by shaking; listen for rattle. If no rattle is heard, replace

Spark Plugs

Replace

Spark Plug Wires/Boots

Check for damage or deterioration

DRIVE/TRANSMISSION PACKAGE

MAINTENANCE POINT

Required Action(s) Important Notes

Drive Shaft Splines

Dealer to check for wear and lubricate

Drive Unit Exhaust Bellow & Clamps

Check for leaks, check clamps

Drive Unit Oil

Check level

Drive Unit Oil

Replace

Power Trim/Tilt

Check for smooth operation

Propeller, Shaft and Rubber Hub

Check for damage or corrosion Lubricate shaft

Sacrificial Anodes

Visual Inspection Replace if eroded more than 30%

Shift Cable

Dealer to replace

Universal Joints, Gimbal Bearing and Engine Alignment

Dealer to inspect for wear and lubricate

Universal Joint Bellows and Clamps

Check for damage, tighten clamps

Universal Joint Bellows and Clamps

Replace

Refer to

Page

77, 83

65

74–75

Refer to

Page

–

63

89–94

37, 88

102–104

95

–

64, 91,

94

64, 91,

94

Calendar Frequency OR Operating Hours

(WHICHEVER COMES FIRST)

Once Every

2 Years

Every 200

Hours

Each

Usage

Monthly

OR

Every 50

Hours

Yearly OR

every 50 hours

Yearly OR

every 50 hours

Yearly

OR

Every 100

Hours

•

Calendar Frequency OR Operating Hours

(WHICHEVER COMES FIRST)

Once Every

2 Years

Every 200

Hours

Each

Usage

Monthly

OR

Every 50

Hours

Yearly

OR

Every 100

Hours

•

OR

•

Once Every

3 Years

OR

Every 300

Hours

•

Once Every

3 Years

OR

Every 300

Hours

•

VPA 7748131 English 09-2007 61

Maintenance

MISCELLANEOUS

MAINTENANCE POINT

Required Action(s) Important Notes

Battery and Connections

Check that all connections are clean & tight

Emergency Stop Switch

Check clip and lanyard

EVC System

Dealer inspection with diagnostic tool

General Inspection of Engine, Drive, and Transom Shield Hardware: Clamps, Fasteners, Screws, Nuts, etc.

Check and tighten, see General Torque Specifications on page 122

Power Steering

Check for smooth operation

Power Steering Fluid

Check level

Remote Control and Shift System

Check for smooth operation

Remote Control and Shift System

Check cable retainer on pivot housing for engagement and secure cable attachment on sterndrive, lubricate cables

Steering System Cables

Check for smooth operation

Steering System Cables

Lubricate

Safety Equipment

Check that all required and recommended equipment is on board

Refer to

Page

71–73

9, 22

–

36, 87

87

27–32

36, 87

11

Calendar Frequency OR Operating Hours

(WHICHEVER COMES FIRST)

Once Every

2 Years

Every 200

Hours

Each

Usage

Monthly

OR

Every 50

Hours

Yearly

OR

Every 100

Hours

•

Yearly OR

every 200 hours

•

Yearly OR

every 50 hours

•

OR

Once Every

3 Years

OR

Every 300

Hours

62 VPA 7748131 English 09-2007

Maintenance

Maintenance of Boat’s Systems

The following sections provide information about the maintenance of various systems aboard your boat, including the engine, drive, transmission, steering, fuel, electrical, and cooling systems. If you intend to do any maintenance on your engine, transmission, and drive, we urge you to be thoroughly familiar with the procedures described in this manual. Always read and follow the safety warnings provided in this manual. If you are uncertain about any procedures described in the manual, or you would like to purchase a workshop manual, please contact your Volvo Penta dealer.

Engine Exhaust System

Periodically inspect the engine exhaust system. Be sure to check for:

 Deteriorated hoses.

 Burned hoses.

 Loose clamps.

22132-1

 Evidence of water leaks.

 Corrosion or blockage in the exhaust manifold

and riser(s).

Check the gasket surface (B), between the exhaust riser (A) and manifold (C), for damage caused by cor- rosion. The components should be replaced if the walls are thin or surface is pitted. Water may leak into the engine if this joint is damaged. If necessary, see your authorized dealer for this inspection.

WARNING! Replace damaged or defective components, and securely tighten all clamps. Any exhaust leak must be repaired before you operate your boat. Exhaust leaks release fumes that can create hazardous conditions for operator and passengers.

VPA 7748131 English 09-2007 63

Maintenance

Drive Unit Bellows

WARNING! If you work on the drive bellows, secure the drive unit in a raised position in such a way that it cannot fall. A falling drive may cause serious injury.

 Check the drive unit bellows for fractures and

deterioration. Barnacle build-up on the bellows may cause punctures; keep the surfaces clean.

 Check tightness of all hose clamps.

 Check the drive unit bellows and clamps

monthly or every 50 operating hours. You may order the bellows separately, or as part of an accessory kit. The accessory kit also includes O-rings, oils, washers, seals, and anodes.

50407

22392-3

 Inspect the inside of the bellows for signs of

contact with the u-joint assembly, which indicates the engine was run at an RPM that was too high while the drive was in the tilted position.

 Be sure the clamps are installed as shown in

the picture.

NOTICE! When washing the drive unit, do not use a

pressure washer. Using a pressure washer will damage the water intake hose and the drive bellows.

23390

64 VPA 7748131 English 09-2007

Maintenance

PCV Valve

The PCV (Positive Crankcase Ventilation) valve controls engine emissions by returning crankcase blowby gases to the engine's intake manifold to be burned. A clogged or stuck PCV valve may result in poor engine performance and stalling. For optimal engine performance, PCV valves should be inspected and replaced according to the maintenance schedule.

The 8.1 Liter engine does not have a PCV valve.

Checking the PCV Valve

To check the PCV valve for clogs or malfunction, use the following steps:

1. Ensure that the engine is turned off and the key has been removed from the ignition.

2. Locate and remove the PCV valve from the valve cover by holding it at the elbow and pulling it out.

NOTICE! Do not pull on the hose to remove the PCV

valve; the hose may come off, leaving the valve in place.

23674

3. Shake the PCV valve. A rattling sound indicates that the valve is not clogged. If you do not hear a rattling sound, chances are the valve is clogged and needs to be replaced.

4. Replace the PCV valve by pressing it firmly back into PCV valve receptacle in the valve cover.

VPA 7748131 English 09-2007 65

Maintenance

Fuel System

DANGER! Gasoline is extremely flammable and highly explosive. ALWAYS turn off the engine before refueling. Do not smoke or allow open flames or sparks near the boat when adding fuel. When filling the gas tank, ground the tank to the source of gasoline by holding the hose nozzle firmly against the side of the deck filler plate, or ground it in some other manner. This action prevents static electricity buildup that could cause sparks and ignite fuel vapors.

22790

22823

Gasoline Recommendations

USE ONLY UNLEADED FUEL. Use lead-free gaso-

line with the following minimum or higher octane specification:

Inside the U.S.: (R+M)/2 (AKI) – 87

Outside the U.S.: (RON) – 90

If fuels with 89 AKI pump posted (93 RON) octane number or higher are used an increase in power can be expected with EFI models.

Mid-grade and premium fuels contain injector cleaners and other additives that protect the fuel system and provide optimum performance.

Gasoline will degrade over time. Always buy your gasoline from a reputable dealer.

NOTICE! Engine damage resulting from the use of a

lower octane gasoline than 87 AKI (90 RON) is considered misuse of the engine. Any resulting engine damage will not be covered by the warranty.

66 VPA 7748131 English 09-2007

22824

NOTICE! Do not use any gasoline that contains

METHANOL. Serious damage will result from the continued use of fuel containing METHANOL. Any resulting engine damage will not be covered by the warranty.

Maintenance

Gasoline Containing Alcohol

Many brands of gasoline being sold today contain alcohol. Two commonly used alcohol additives are Ethanol (ethyl alcohol) and Methanol (CH

OH), also

3

called methyl alcohol.

See your boat owner’s manual to see if the boat’s fuel system is compatible with alcohol blended fuels. If it is, your engine may be operated using gasoline blended with no more than 10% Ethanol meeting the minimum octane specification.

If you use gasoline that contains ethanol, be aware of the following:

• The engine will operate leaner with ethanol

blended fuel. This may cause engine problems such as vapor lock, low speed stall, or hard starting.

• Ethanol blended fuels attract and hold moisture.

Moisture inside fuel tanks can cause corrosion of the tank material. Inspect fuel tanks at least annually. Replace fuel tanks if inspection indicates leakage or corrosion.

22823

Leaded Fuels

EFI models: Some marinas sell fuel with lead addi-

tives. Do not use leaded fuel, as it may block the fuel injectors and cause leakage.

DANGER! Fuel leakage can contribute to a fire and/or explosion. Frequently inspect nonmetallic parts of the engine’s fuel system and replace if excessive stiffness, deterioration, or fuel leakage is found.

DANGER! To prevent fire and explosion, perform all service procedures with the engine turned OFF.

DANGER! Failure to inspect your work may allow fuel leakage to go undetected. This could become a fire or explosion hazard.

After completing service procedures, start engine and check entire fuel system for possible leaks.

To prevent fire and explosion, Volvo Penta fuel system components meet U.S. Coast Guard requirements for fuel and fuel vapor containment. Do not substitute automotive or other non-approved parts.

VPA 7748131 English 09-2007 67

Maintenance

Electronic Fuel Injection

The electronic fuel injection (EFI, not shown) fuel metering system delivers the correct amount of fuel to the engine under all operating conditions. The EFI system is controlled by a microprocessor, and requires no periodic maintenance or adjustment. If operational problems occur, see your Volvo Penta dealer.

Detonation (Spark Knock)

Detonation, or spark knock, is continually monitored by the electronic fuel injection (EFI) system. The EFI’s computer (ECM) will automatically alter spark advance to help prevent engine damage if knock is detected, and there will be a slight loss of power.

Preventing Gum Formation and Corrosion

To prevent gum formation and corrosion in the fuel system, use a fuel stabilizer in the gasoline if it will be in the tank for more than two weeks or if the boat is being prepared for winter storage. After adding fuel stabilizer, the engine should be run for ten minutes to allow stabilized fuel to reach all points of the fuel system. Fuel stabilizer is available from your Volvo Penta dealer.

68 VPA 7748131 English 09-2007

23744

Maintenance

Flame Arrestor

Clean the flame arrestor (1 or 2) every 50 operating hours.

WARNING! Use extreme care when removing flame arrestor on 8.1L engines (2). The electronic throttle plate, located behind the flame arrestor, has moving parts that are sharp and may severely cut or amputate fingers.

• Clean in solvent, air dry, and inspect for damage.

• Replace if damaged.

• Reinstall flame arrestor; make sure unit is

securely fastened.

To prevent fire and explosion in the engine compartment, the flame arrestor must always be in place, properly secured, and undamaged.

Electric Fuel Pumps

WARNING! Check fuel pumps (A and B) frequently for signs of fuel leakage. If leakage occurs, have the fuel pump serviced immediately by your Volvo Penta dealer.

EFI engines have two electric fuel pumps:

• A high-pressure pump (A) to supply the fuel

injectors.

• A low-pressure pump (B) to bring fuel from the

boat tank to the engine.

Both pumps are protected by a single 20-amp fuse. The pumps will operate only when the engine is cranking or running. If a pump does not function, check the fuses and replace them if necessary. See your Volvo Penta dealer if further service is required.

NOTICE! Do not run engine out of fuel or run the elec-

tric fuel pumps dry more than 20 seconds. Running the electric fuel pumps dry will damage the fuel pumps.

22825

VPA 7748131 English 09-2007 69

Maintenance

22825-1

Fuel Filter

All models have a fuel filter (1) in the fuel line before the fuel pump.

NOTICE! Volvo Penta EFI engines require a special

marine filter with a 10 micron filtering capability. Do not substitute any other type of filter.

NOTICE! Accumulation of water and other fuel con-

taminants may form corrosive compounds that can damage the fuel filter, and result in fuel leakage. For this reason, annual replacement of the fuel filter is required to avoid risk of explosion or fire.

Engine Fuel Filter Replacement

Run the bilge blower for at least five minutes to vent the engine compartment, then start the engine and check for leakage. Smell for fuel in the bilge. Clean up the bilge until fuel cannot be detected by smell.

22839

NOTICE! A loud whining noise at idle may be due to

a restricted fuel filter causing a noisy fuel pump. Operating the engine with a restricted filter may damage the pressure regulator or fuel pumps. See your Volvo Penta dealer if the pump makes an unusual noise.

DANGER! If you can smell fuel, turn the engine off immediately - EXPLOSION AND FIRE ARE AN EXTREME DANGER.

DANGER! Turn off the main battery switch or disconnect the battery to prevent stray sparks.

1. Turn off the engine.

2. Unscrew fuel filter, remove, and discard.

DANGER! The old fuel filter contains flammable fuel. Dispose of safely.

3. Using clean engine oil, lightly lubricate the gasket (C) and inner seal (D) on new fuel filter.

4. Screw on fuel filter and hand-tighten, following instructions on filter.

5. Clean up any spilled fuel.

6. Turn on the main battery switch or reconnect the battery.

7. Run the bilge blower for at least five minutes to vent the engine compartment.

8. Start the engine and check for leakage.

9. Smell for fuel in the bilge.

10. Clean up the bilge until fuel cannot be detected by smell.

70 VPA 7748131 English 09-2007

Maintenance

Electrical System

The engine’s electrical system features cranking, charging, ignition, and trim/tilt circuits. A battery and all necessary wiring provide power.

WARNING! Do not expose the battery to electrical sparks or an open flame. Do not use jumper cables and a booster battery to start the engine. Remove the battery from the boat to recharge. Do not recharge the battery in the boat.

NOTICE! The battery terminal connections must always be insulated. If the battery mounting system does not

cover the connections, install protective covers. This will help prevent shorting or arcing at the battery terminals.

NOTICE! If electrical connections are reversed, or wires are disconnected when the key switch is ON or the engine

is running, sensitive electrical components may be immediately damaged. Do not turn off the main battery switch until the engine has stopped.

Battery Cables

The following are the minimum specifications for multistrand copper cables from the motor to the battery for all models. The maximum length is 20 feet per cable, regardless of diameter.

18633

• 0 to 10 ft. (3.05 m) require a 1/0 AWG (80 MWG)

cable.

• 10 to 15 ft. (3.05 to 4.6 m) require a 2/0 AWG

(100 MWG) cable.

• 15 to 20 ft. (4.6 to 6.1 m) require a 3/0 AWG (120

MWG) cable.

NOTICE! Do not use aluminum core battery cables.

Failure to use battery cables of recommended gauge and material could result in poor starting and electrical component damage.

Batteries and Connections

Battery Requirements:

All EFI engines ................... 650 CCA non-deep cycle

NOTICE! Do not use deep cycle batteries on EFI en-

gines. A deep cycle battery, while it may have enough cold cranking amps (CCA), will cause problems with EFI engines. The correct starting battery for all Volvo Penta EFI engines is a standard marine battery with a minimum of 650 CCA and a minimum of 135 minutes reserve capacity.

22826

VPA 7748131 English 09-2007 71

Maintenance

22827

• The battery used to start the engine must be a

12-volt, heavy duty marine battery, with adequate amperage for the engine model installed on your boat. Refer to the section entitled Tec h - nical Data on page 115 for additional information.

• All other batteries must be heavy duty and con-

structed for marine use. They can be either vented/refillable, maintenance-free, or deepcycle with a CCA.

• Use bolts and nuts to secure battery cables to

the battery terminals. Do not use wing nuts to secure battery cables, even if they were supplied with the battery.

• Tighten all battery connections. Loose battery

connections may cause damage to the engine’s electrical system.

22840

The service life of your battery depends largely on how it is maintained.

• Keep batteries dry and clean. Oxidation or dirt on the battery and battery terminals may cause short circuits,

voltage drops, and discharges (especially in damp weather).

• Clean battery terminals and leads to remove oxidation.

• Tighten cable terminals tightly.

• Spray battery terminals and connections with an anti corrosive agent, or coat them with petroleum jelly.

• Check that all other electrical connections are dry and free of oxidation, and that there are no loose connec-

tions.

• Always switch off the charging circuit before removing the battery charger connectors.

• Inspect your battery at regular intervals for specific gravity (state of charge), individual cell water level, clean-

liness and tight, greased connections.

• If the battery has become discharged for no apparent reason, check all electrical system components for

malfunction or a switch left ON, before installing a recharged battery.

• Electrolyte levels should be above the plates in the battery and no higher than the fill indicator level. Top off

if necessary, using distilled water. After topping off, run the engine at fast idle for at least 30 minutes to charge the battery.

WARNING! Battery electrolyte is a corrosive acid and should be handled with care. If you spill or splash electrolyte on any part of the body, immediately flush the exposed area with liberal amounts of water and seek medical attention as soon as possible.

NOTICE! Some maintenance-free batteries have special instructions. Make sure to follow the battery manufactur-

ers instructions carefully.

72 VPA 7748131 English 09-2007

Maintenance

Battery Replacement

DANGER! Fumes vented during battery charging may cause an explosion. Failure to follow the safety precautions below may result in electrical sparks igniting fuel vapors causing fire or explosion.

NOTICE! When replacing your battery, read and understand the information supplied with it before you begin in-

stallation.

1. Service electrical components only while the motor is off. Be careful when identifying positive and negative battery cables and terminals. If you touch the wrong terminal with a battery cable, even briefly, the motor’s charging system could be damaged.

2. Operate the boat’s bilge blower for at least 5 minutes prior to servicing battery.

3. Open the engine cover or hatch and check the boat’s bilge area for gasoline fumes. If any fumes can be detected by smell, do not operate the boat until you find the source, clean up the spill, and correct the cause.

4. Do not connect cables to battery until all other electrical connections have been made.

5. Make sure the ignition switch is OFF before removing or installing electrical equipment, checking any electrical connections, or installing battery cables.

Multiple Batteries and Selector Switch

See your Volvo Penta dealer for multiple battery installation recommendations.

22827-2

If your boat is equipped with multiple batteries and a selector switch, the engine should be operated with the selector switch set to the ALL position. This will provide charging system output to all batteries.

A battery isolator is recommended if batteries will be switched for individual operation.

Distributor Cap and Rotor

1. Remove the distributor cap screws (1) using a

1

T20 screwdriver.

Torx

2. Remove the rotor screws (3) using a Torx T15 screwdriver.

3. Clean the distributor cap (2) and rotor (4) using compressed air. Inspect for damage, excessive wear, or corrosion. If necessary, replace these components with genuine Volvo Penta parts.

4. Reattach the rotor, torquing screws to 18 in. lb. (2 Nm).

5. Reattach the distributor cap, torquing screws to 21 in. lb. (2.4 Nm). If you reuse the original screws, apply thread locking compound (PN 1161053).

Be sure spark plug leads are replaced in the correct firing order. Firing order information is provided in the section entitled Technical Data on page 115.

23765

VPA 7748131 English 09-2007 73

1. Torx is a registered trademark of Textron Inc. DBA Camcar

Division of Textron Inc.

Maintenance

Spark Plugs

23172

Before installing new spark plugs, always check for proper type and gap

1

. Incorrect spark plugs can cause operational problems and possible internal engine damage.

Before installing a spark plug, the spark plug seat in the cylinder head should be wiped clean. Tighten plugs to the proper torque value

1

. Make sure the spark

plug terminals are fully seated on the spark plugs.

When spark plug leads are removed, be sure they are replaced in the correct firing order

1

.

DANGER!

• Avoid abusive handling that could crack the

spark plug’s ceramic body (A). Damaged spark plugs can emit external sparks that could ignite any fuel vapors in the engine compartment, resulting in fire or explosion.

• Do not operate engine if spark plug boots or

high-tension leads are torn or cracked. This condition could allow external sparks which could ignite any fuel vapors in the engine compartment, resulting in fire or explosion.

CAUTION! To prevent possible injury caused by someone inadvertently starting the engine, remove the ignition keys from each starting location (especially if the engine room/engine compartment cannot be seen from various remote starting positions such as a flybridge or enclosed cabin).

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Checking and Changing Spark Plugs

1. Twist and pull only on the spark plug wire boot

(pulling on wire may cause separation of the core of the wire).

2. Remove spark plugs using a 5/8-inch spark plug

socket or a 5/8-inch box wrench. Use care to avoid cracking the spark plug insulators (D).

3. Carefully inspect the insulators and electrodes of

all spark plugs.

 Replace any spark plug which has a cracked

or broken insulator or which has loose electrodes (B).

 If the insulator is worn away around the center

electrode (C), or the electrodes are burned or worn, the spark plug is worn out and should be discarded.

 Spark plugs that are in good condition, except

for carbon or oxide deposits, should be thoroughly cleaned and gapped.

1. For additional information, see Technical Data on

page 115.

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Maintenance

The spark plug wires are a special resistance type. The core is carbon-impregnated linen. This type wire is superior to copper core wire in its resistance to crossfire; however, it is more easily damaged than copper core. For this reason, pull on the spark plug boots to remove the spark plug wires, rather than pulling on the wire insulation. If the wire is stretched, the core may be broken with no evidence of damage on the outer insulation. If the core is broken, it will cause misfiring. In the case of wire damage, it is necessary to replace the complete wire assembly since a satisfactory repair cannot be made.

4. Clean ignition wires with a cloth moistened in kerosene, and wipe dry. Bend wires to check for brittle, cracked or loose insulation. Defective insulation may result in misfiring, cross-firing, or spark to ground; therefore, defective wires must be replaced.

5. If the wires are in good condition, clean any terminals that are corroded. Replace any that are broken or distorted. Replace any wires with broken or deteriorated cable nipples or spark plug boots.

6. Clean spark plugs.

Spark plugs that have carbon or oxide deposits should be cleaned in a blast type spark plug cleaner. Scraping with a pointed tool will not properly remove the deposits and may damage the insulator. If spark plugs have a wet or oily deposit, dip them in a degreasing solvent and dry thoroughly with compressed air. Oily plugs will cause the cleaning compound to pack in the shell. Carefully follow the instructions of the manufacturer of the cleaner being used. Clean each plug until the interior of the shell and entire insulator are cleaned. Avoid excessive blasting.

7. Examine interior of plug in good light. Remove any cleaning compound with compressed air. If traces of carbon or oxide remain in plug, finish the cleaning with a light blasting operation. Clean firing surfaces of center and side electrodes with several strokes of a fine cut file.

8. When spark plugs have been thoroughly cleaned, carefully inspect them for cracks or other defects that may not have been visible before cleaning.

9. Use a round wire feeler gauge to check the gap between the spark plug electrodes. (Flat feeler gauges will not give a correct measurement if the electrodes are worn.) Adjust gap by bending the side electrode only. Bending the center electrode will crack the insulator. Setting the spark plug gap to any other specification in an attempt to improve idle or affect engine performance is not recommended.

10. See the diagrams for correct installation of spark plugs and wires.

For proper engine performance it is very important that the correct spark plugs be used. When installing spark plugs, make sure that the threads in the cylinder head and all surfaces on plugs and in cylinder heads are clean. Tighten spark plugs the specified amount. All engines use tapered seat plugs without gaskets.

DANGER! Do not operate engine if spark plug boots or high-tension leads are torn or cracked. This condition can allow external sparks, which could ignite any fuel vapors in the engine compartment.

22843

Spark plug wires must be arranged between the distributor cap and spark plugs in the order of firing sequence. If spark plug wires are not correctly installed, misfiring or cross-firing will result.

8.1liter engines use a distributorless ignition system

with one coil per cylinder. Refer to the section entitled Technical Data on page 115 for correct firing order information.

Circuit Breakers and Fuses

The engine and boat’s electrical system is protected against current overload by a circuit breaker and fuses.

• If the circuit breaker trips, press button to reset.

• Replace any blown fuses.

NOTICE! Circuit breakers or fuses that repeatedly fail

indicate a problem that requires immediate attention. See your Volvo Penta dealer.

NOTICE! If electrical connections are reversed, or

connections removed when the key switch is on or the engine is running, the electrical system may be immediately damaged.

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Maintenance

Belt Replacement

CAUTION! To prevent possible injury caused by someone inadvertently starting the engine, remove the ignition keys from each starting location (especially if the engine room/engine compartment cannot be seen from various remote starting positions such as a flybridge or enclosed cabin).

Serpentine Belt Engines

All engine models use a serpentine belt, which is a continuous-loop belt threaded through the alternator pulley, circulating pump pulley, idler pulley, and power steering pump pulley.

This single belt replaces two separate belts (alternator and power steering pump belts). The serpentine belt tension is adjusted automatically and requires no tension adjustments. However, at least once per year, have your Volvo Penta dealer check the serpentine belt for wear or inspect the belt yourself for cracks, check marks, dry rot, exposed cords, oil or grease. An ideal time to perform this check is when you have the gimbal bearing lubricated.

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Alternatively, you may check the indicators, located on the automatic tensioner housing, to determine the amount of wear. When tick marks C and D coincide, it’s time to replace the serpentine belt.

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Maintenance

Cooling System

If a situation should occur where the cooling system is unable to provide adequate cooling, be sure to check three possible causes before continuing to operate the engine:

• Drive water intakes blocked. Tilt the drive up and look for obstructions to the water intakes (e.g., seaweed,

plastic bags, etc.).

• Raw water pump impeller damaged or blocked. For additional information, see Impeller: Checking & Replac-

ing on page 83.

• Faulty engine thermostat. For additional information, see Replacing the Engine Thermostat on page 78.

Raw Water System

Various Volvo Penta engines have a thermostat-controlled raw water cooling system.

1. Cool water is drawn in through raw water intake (A) by an impeller (C) connected to the raw water pump (D) mounted on the front of the engine.

2. Water is pumped to the engine and routed by circulating water through the cooling system (B).

3. A thermostat inside the engine determines the amount of water to be taken in, recirculated, and discharged to control the engine’s operating temperatures.

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Closed Cooling System (F-Series)

Various Volvo Penta engines have a thermostat-controlled, fresh water cooling system.

1. Cool water is drawn in through raw water intake (E) by an impeller (F) connected to the raw water pump (G) mounted on the front of the engine.

2. Water is pumped (H) to the heat exchanger (I), which cools the engine cooling fluid (J). The raw water is then routed to the exhaust manifolds where it is mixed with exhaust and dumped overboard through the sterndrive exhaust port.

3. The engine cooling fluid is recirculated between the engine and the heat exchanger by the engine circulation pump (K).

4. A thermostat inside the engine determines the amount of water to be taken in and circulated to the heat exchanger, then discharged to control the engine’s operating temperatures.

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Maintenance

Engine Overheating

If the engine overheats at high engine speeds, the engine protection mode feature will activate and:

• Engine speed will be automatically reduced to

approximately 2500 RPM. The engine will not operate above 2500 RPM. If an engine overheat alarm has been installed, an audible warning horn will sound.

• The engine protection mode feature will remain

active until the engine has been reduced to idle speed and the overheating problem is corrected. For additional information, see Engine Protec- tion Mode on page 26.

NOTICE! Do not remove the thermostat from the en-

gine as the engine is likely to overheat.

While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your boat does not have an audible alarm available, we strongly recommend that you contact your dealer to have one installed.

Replacing the Engine Thermostat

5.0–5.7L Engines (Raw Water Cooled)

1. Loosen and remove long bolt 1; save for reuse.

2. Place lifting eye 2 in a secure location; you will need to reattach it later.

3. Loosen and remove short bolt 3; save for reuse.

4. Remove thermostat housing 4.

5. Remove thermostat 5, O-ring 6, and gasket 7 from intake manifold 8. Discard gasket and thermostat. Inspect O-ring and, if damaged, replace.

6. Clean intake manifold and thermostat housing surfaces where the gasket makes contact. Remove any remnants of the old gasket.

NOTICE! Take care not to drop any debris into the in-

take manifold. Place a rag in the intake manifold to keep debris out; remove when cleaning is completed.

7. Place new gasket, new thermostat, and the O-ring into the groove in the intake manifold.

8. Replace thermostat housing.

9. Install bolts and lifting eye.

10. Torque bolts to18–30 ft. lb. (25–41 Nm).

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5.0–5.7L Engines (Closed Cooling System)

1. Loosen and remove long bolt 1 and short bolt 2; save for reuse.

2. Remove upper thermostat housing 3.

3. Remove gasket 4, O-ring 5, and thermostat 6 from lower thermostat housing 7. Discard gasket and thermostat. Inspect O-ring and, if damaged, replace.

4. Clean thermostat housing surfaces where the gasket makes contact. Remove any remnants of the old gasket.

NOTICE! Take care not to drop any debris into the

thermostat housings. Place rags in the housings to keep debris out; remove when cleaning is completed.

5. Place new gasket, new thermostat, and the Oring into the groove in the lower thermostat housing.

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6. Replace upper thermostat housing.

7. Install bolts and torque to18–30 ft. lb. (25–41 Nm).

8.1 Liter Engines (Raw Water Cooled)

1. Loosen and remove long bolt 1, washer 2, and short bolt 3; save for reuse.

2. Remove thermostat housing 4.

3. Remove thermostat 5, small O-ring 6, and large O-ring 7, from cross-over pipe housing 8. Discard thermostat. Inspect O-rings and, if damaged, replace.

4. Place new thermostat and O-rings into the groove in the cross-over pipe housing.

5. Replace upper thermostat housing.

6. Install bolts and washer and torque to18–30 ft. lb. (25–41 Nm).

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Maintenance

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8.1 Liter Engines (Closed Cooling System)

1. Loosen and remove bolts 1; save for reuse.

2. Remove upper thermostat housing 2.

3. Remove O-ring 3, thermostat 4, and gasket 5, from lower thermostat housing 6. Discard gasket and thermostat. Inspect O-ring and, if damaged, replace.

4. Clean thermostat housing surfaces where the gasket makes contact. Remove any remnants of the old gasket.

NOTICE! Take care not to drop any debris into the

thermostat housings. Place rags in the housings to keep debris out; remove when cleaning is completed.

5. Place new gasket, new thermostat, and the Oring into the groove in the lower thermostat housing.

6. Replace upper thermostat housing.

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NOTICE! When re-installing the blue cap on the fresh

water flush hose, tighten it by hand, then tighten 1/4 turn using a wrench. If the cap is too loose, air may be sucked in, causing the engine to overheat, resulting in damage.

7. Install bolts and torque to18–30 ft. lb. (25–41 Nm).

Engine Flush

Volvo Penta engines incorporate an engine flushing port designed to flush the engine with fresh water while the engine is running. If flushing the engine with the boat in the water, the engine should not be run higher than idle or sea water may be drawn in with the fresh water.

NOTICE! When flushing the engine with the boat in

the water, fresh water pressure must be 17 psi (117 kPa) or greater.

1. If the engine is running, shut it down.

2. Remove the blue plastic cap from the hose that is clamped to the starboard side of the engine. It is marked with the running engine flush symbol (1).

3. Connect a water hose from a fresh water source to the flush connector on the engine (2).

4. Turn water on full and start the engine.

5. Let engine idle until engine temperature stabilizes at its normal operating range. This will allow the thermostat to open and ensure the fresh water circulates throughout the engine.

6. After engine is flushed, shut engine the down.

7. Disconnect water hose and reinstall the cap.

Drain the engine if freezing temperatures are expected. For details on draining the engine, please refer to the section entitled Draining the Cooling System on page 81.

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Maintenance

Draining the Cooling System

NOTICE! When temperatures drop below freezing, failure to completely drain the cooling system will result in se-

rious damage to the engine and exhaust manifolds. To assure complete drainage, probe all drain openings with a piece of wire to remove any blockage.

NOTICE! The following steps are very important in protecting your engine from damage in freezing conditions. If

unsure of how to perform any of the following steps, see your Volvo Penta dealer for a complete end-ofseason/winterization service. Freeze damage to the engine package is not covered by your Volvo Penta limited warranty.

NOTICE! When draining the starboard manifold, take care to direct the drained water away from the starter to

prevent water damage to the starter.

• Perform these procedures with the boat out of

the water. It will prevent damage to cooling system components if temperatures drop below freezing.

• When draining the engine, raise or lower the

bow of the boat to keep the engine level. This will provide for complete drainage of the block and manifold. If the bow of the boat is higher or

22800

lower than the stern, some water may be trapped in the block.

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Raw Water Cooled Engines

1. With the engine turned off, locate and open the engine drain petcocks (B) located on both sides of the engine block.

NOTICE! Be sure that all water is drained from the

engine. If no water drains when the petcocks are opened, remove the petcocks and use a piece of wire to clear any obstructions from the drain hole. Failure to drain all the water from the engine may result in engine damage during freezing temperatures.

2. Remove drain plugs from exhaust manifolds (A). Raise or lower the bow of the boat to ensure complete drainage. Probe the drains with a wire to ensure rust particles have not blocked the drain. After the water has completely drained, reinstall the drain plugs and tighten securely.

3. Note the hose orientation on the raw water pump. Loosen the hose clamps and remove the hoses from the raw water pump. Loosen the hose clamp on the large diameter hose and remove it from the circulation pump.

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Maintenance

4. Crank the engine briefly, (1 or 2 crankshaft revolutions) but do not start the engine, to clear the water from the pump.

NOTICE! It may be necessary to turn the ignition key

back to the OFF position 0 to prevent the engine from starting.

5. Loosen clamp (C) and remove hose (D) from fuel pump. Allow water to drain from hose.

6. Reinstall all hoses and secure all clamps in the same orientation as removed.

NOTICE! Failure to connect the raw water pump hos-

es in the correct orientation may damage the raw water pump impeller.

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Draining the Closed Cooling System

5.0–5.7 Liter Engines (F-Series)

NOTICE! Check the coolant level and antifreeze con-

centration (check coolant manufacturer’s instructions). Make sure the coolant’s freeze point is adequate for expected temperatures. Failure to maintain adequate antifreeze may result in engine damage during freezing temperatures.

To drain the raw water system of your Volvo Penta engine (with factory installed closed cooling):

1. With the engine turned off locate and loosen the lower drain cap from the heat exchanger (1). After water has completely drained, retighten the lower drain cap of the heat exchanger to 18-30 ft. lb. (25-41 Nm).

2. Note the hose orientation on the raw water pump (G). Loosen the hose clamps (2) and remove the hoses (E & H) from the raw water pump. Crank the engine briefly, (1 or 2 crankshaft revolutions) but do not start the engine, to clear the water from the pump. Reinstall the hoses and secure the clamps in the same orientation as removed.

3. Remove drain plugs from exhaust manifolds. Change the level of the boat to ensure complete drainage. Probe the drains with a wire to ensure rust particles have not blocked the drain. After water is completely drained, reinstall drain plugs and tighten securely.

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Maintenance

8.1 Liter Engines (F-Series)

NOTICE! Check the coolant level and antifreeze con-

centration (check coolant manufacturer’s instructions). Make sure the coolant’s freeze point is adequate for expected temperatures. Failure to maintain adequate antifreeze may result in engine damage during freezing temperatures.

1. With the engine turned off locate and loosen the lower drain cap from the heat exchanger (1). After water has completely drained, retighten the lower drain cap of the heat exchanger to 18-30 ft. lb. (25-41 Nm).

2. Note the hose orientation on the raw water pump (G). Loosen the hose clamps (2) and remove the hoses (E, H, & L) from the raw water pump and heat exchanger. Crank the engine briefly, (1 or 2 crankshaft revolutions) but do not start the engine, to clear the water from the pump. Reinstall the hoses and secure the clamps in the same orientation as removed.

23679

3. Remove drain plugs from exhaust manifolds. Change the level of the boat to ensure complete drainage. Probe the drains with a wire to ensure rust particles have not blocked the drain. After water is completely drained, reinstall drain plugs and tighten securely.

Impeller: Checking & Replacing

NOTICE! If the engine is installed so that the seawa-

ter pump is located under the water line, there is a risk of water penetration. If you have a seacock installed, close it now.

NOTICE! Always carry a spare impeller on board.

1. Remove the hose clamps and hoses from pump.

2. Loosen the four screws (1) and remove the housing (2).

3. Inspect the impeller (3). If there are cracks, signs of burning or melting on the edges, or any other visible defects, the impeller must be replaced. Inspect the O-ring (4) for nicks, cuts, and wear. Replace as necessary.

4. Lubricate the pump housing with non-petroleum based lubricant, suitable for rubber, such as glycerine. If you have purchased the Volvo Penta impeller kit, a packet of glycerine is included.

5. Reinstall the impeller. Reinstall the housing.

6. Install the hoses and hose clamps.

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Maintenance

Lubrication System

Engine/Crankcase Oil

To obtain the best engine performance and engine life, Volvo Penta recommends synthetic engine oil labelled for API Service CF/SH and ILSAC GF-4, or you may use an engine oil with the recommended quality and viscosity. Engine oils are specified by API service, letter designations, and SAE viscosity numbers. Refer to oil identification symbol on the container.

Initial factory fill is a high quality motor oil for API Service CF/SH and ILSAC GF-4. During the break-in period (20 hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated. The oil level should be maintained between the ADD and FULL marks on the dipstick. The space between the marks represents approximately one quart (one liter). For oil level dipstick location, refer to the photographs in the section entitled Features on page 43.

The sections entitled Technical Data on page 115 and Maintenance Schedule on page 60 provide detailed information about oil filter type and service intervals.

When you add or change engine oil, use Volvo Penta engine oils for gasoline engines. Use the viscosity chart to select the SAE viscosity that matches the temperature range in which you expect to operate.

Lowest Anticipated

Temperature

32° F (0° C) — above

0° F (-18° C) — 32° F (0° C) SAE 20W-20 Below 0° F (-18° C) SAE 10W

NOTICE! Use Volvo Penta Engine Oil, Synthetic or

Mineral, recommended for 0°F (-18°C) and above. For additional information, see Maintenance Schedule on page 60.

Recommended SAE

Viscosity Oils

SAE 30 SAE 20W/50 SAE 15W/50

All models are required to use a mineral-based oil for the first 150 hours. After the first 150 hours, the operator may continue to use mineral oil (requiring an oil change at 100 hour intervals or once per season) or switch to synthetic oil (requiring an oil change at 200 hour intervals or once per season). Switching between mineral based oils and synthetic oils is not recommended. For additional information, see Maintenance Schedule on page 60.

Use single viscosity oils in markets where available. The use of multi-viscosity oils such as 10W-30 and 10W-40 is not recommended unless single viscosity oils are unavailable.

At the first service interval (50 hours), change the crankcase oil and replace the oil filter. Refer to the Maintenance Schedule for recommended oil change intervals.

WARNING! Use only parts that are U.S.C.G. approved for marine use. Substituting automotive or generally supplied parts and hardware may result in product malfunction and possible injury to the operator and/or passengers. Never use parts of unknown quality.

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Maintenance

Checking Engine Oil Level

The oil level must be between the two level marks on the dipstick C. If engine is not in a horizontal position, the oil level on the dipstick will not be accurate. If the oil level is checked with a cold engine, the oil level on the dipstick could be above the actual level. If the oil level is checked directly after shutting the engine off the oil level on the dipstick will be low. To get an accurate oil level reading on the dipstick:

51216

1. Run the engine to normal operating temperature, then shut off engine and wait at least 5 minutes.

2. Remove the dipstick and check oil level.

3. Add oil as necessary to maintain the proper level.

NOTICE! Do not allow the crankcase oil level to go

below the ADD mark E, and do not fill above the FULL mark D. Overfilling results in high operating temperatures, foaming (air in oil), loss of power, and overall reduced engine life.

Changing Engine Oil

Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting, fuel economy, combustion chamber deposits, and engine wear.

1. Run the engine at idle speed to warm the crankcase oil (for easier removal).

2. Turn off the engine.

3. Remove oil dipstick. Using the special fitting provided on the tube, drain the oil from the crankcase through the dipstick tube. This special fitting is provided so that the oil does not have to be drained into the bilge.

4. Withdraw oil with a suction pump.

You may purchase either a manual or an electric suction pump from any marine supply store or from your Volvo Penta dealer.

5. Dispose of used oil according to any applicable federal, state, and local environmental regulations.

1011024

6. Replace the oil filter.

7. Remove the oil fill cap and fill the crankcase to the specified capacity with Volvo Penta premium engine oil.

For additional information, see Maintenance Schedule on page 60.

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Maintenance

51217

Changing the Oil Filter

Replace the oil filter whenever the engine oil is changed.

WARNING! Hot oil and hot surfaces can cause burns.

1. To remove, unscrew filter canister cap A counterclockwise. Wait a few minutes to allow any remaining oil to drain.

2. Remove the used filter D from canister E or canister cap and discard. Dispose of used filter according to all applicable federal, state, and local environmental regulations.

3. When replacing the O-ring B, coat it with a thin layer of clean engine oil. The O-ring fits in the widest groove below cap rim (second groove down).

4. Slide a new filter onto the filter support C. Screw the cap back onto the canister. Using a 36 mm socket, tighten to 18.4–22.1 ft. lb (25–30 Nm).

5. Fill the engine with new oil. Run engine and check for leaks. Do not run engine without water. Recheck the oil level once the engine has stopped.

Shaft Spline and Bearing Lubrication

The primary shaft and bearings must be lubricated each year and whenever the drive unit is removed. This procedure requires the removal of the drive unit; therefore, your Volvo Penta dealer should do it. An ideal time to have this done is during the winterization process or in the spring when preparing to launch for the first time. Failure to have primary shaft splines and bearings lubricated each year may result in damage to the drive unit or seizure in the engine coupler.

Tie Rod (Twin Installations Only)

Check the rod connecting the drive units, particularly if you hit an obstacle. If the tie rod is bent, loose, or damaged, have it serviced immediately by your Volvo Penta dealer. In the meantime, operate your boat at slow speeds only.

CAUTION! The tie bar is an integral part of the steering system and is a vital safety part. A damaged tie rod may hinder steering operation or render it completely ineffective. Always replace a damaged tie bar. Never try to straighten or weld a damaged tie rod.

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22850

Maintenance

Steering System

1. Check steering and throttle cables for cracks and wear. Check all along the length of the cable, as shown in the diagram. Replace the cables if you suspect that they are not in optimum condition.

2. Check steering system hoses for cracks, leaks, and wear. Replace any hoses that you suspect are not in optimum condition.

Power Steering Reservoir Fluid Level

Whenever you check the engine oil, also check the steering reservoir fluid level. The fluid level must be above the “Min” line and below the “Max” line. If needed, add Volvo Penta Power Trim/Tilt and Steering Fluid. Do not overfill the pump reservoir.

NOTICE! Never fill the steering system with oil of un-

known quality. Non-recommended oil may cause steering operation impairment or component damage.

51215

Do not allow contaminants to enter the reservoir when checking or filling the oil level.

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Maintenance

50408.

Power Trim/Tilt-Fluid: SX-A/DPS-A

The trim/tilt assembly is a closed hydraulic system that includes the trim pump assembly, trim cylinders and hydraulic lines. No regular oil level check is required unless trim system performance is poor.

If system performance is poor, check fluid level in pump.

1. Trim drive to full down position.

NOTICE! Failure to trim the drive to full down position

when checking and filling the trim pump reservoir will result in an inaccurate fluid level; this may damage the trim system.

2. Turn drive full to port to provide better access to pump.

NOTICE! Clean area around cap before removing to

check oil level. Debris in oil will damage the trim system.

3. Remove cap in pump P. Oil level should be at top of cap hole.

If necessary, add Volvo Penta Power Trim/Tilt and Steering Fluid.

4. Replace cap and tighten to 18–35 in. lb. (2–4 Nm).

Power Trim/Tilt Fluid: XDP-B

The power trim and tilt assembly contains an electric motor, hydraulic pump, and reservoir.

At the beginning of each boating season, check the fluid level in the reservoir:

1. With the drive unit trimmed in (down) as far as possible, remove the fill cap E.

NOTICE! Clean area around cap before removing to

check oil level. Debris in oil will damage trim system.

2. Check the fluid level. It should be between the minimum and maximum marks (D & C) on the reservoir. If needed, add Volvo Penta Power Trim/Tilt and Steering Fluid.

NOTICE! When topping up, use SAE 30W Engine Oil

only.

3. Replace the fill cap and tighten securely.

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Maintenance

Drive Components (SX-A/DPS-A)

The drive unit is filled at the factory with Volvo Penta Synthetic Gear Oil. Change lubricant every 100 hours or every 12 months, whichever occurs first. Use Volvo Penta Synthetic GL5 75W90 Gearcase Lubricant.

Drive Unit Lubrication (SX-A/DPS-A)

Checking the Drive Unit Lubricant (SX-A/DPS-A)

NOTICE! Improper oil level, under- or overfilled, will

result in serious internal sterndrive damage.

Check lubricant (oil) level in sterndrive at each usage. Oil level and condition checks are the best ways to catch sterndrive problems before serious damage occurs.

1. Screw dipstick fully into hole, then remove.

2. Check oil level on dipstick. Oil should show on flat portion F of dipstick.

If oil level is low, add small amounts through dipstick opening until oil is at proper level.

50398

If level is too high, remove until oil is at proper level. See oil drain procedure below.

3. Check O-ring on dipstick for wear or nicks. Replace if needed. Tighten dipstick to 48–72 in. lb. (5.4–8.1 Nm).

During oil level check, inspect oil for signs of water intrusion. The oil should be amber in color. Milky looking oil indicates water mixed with the oil. Also check for metal or other debris in oil. If moisture or metal flakes appear in the drive unit oil, take the boat to your Volvo Penta dealer.

Draining and Filling the Drive Unit (SX-A/DPS-A)

NOTICE! After oil change, check level with dipstick

before operating drive.

When a complete change of sterndrive oil is required, proceed as follows:

1. Remove propeller(s). Oil drain plug is located in front of propeller(s). For additional information, see Propeller Care on page 102.

2. Place sterndrive in full down position.

3. Place a 4-quart or larger drain pan under lower gearcase skeg to catch oil.

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Maintenance

4. Remove oil drain plug.

5. Remove dipstick (top of sterndrive). Removing dipstick vents drive to improve oil draining.

6. Allow oil to drain completely.

7. Check magnet on drain plug for metal. A very fine metal powder on magnet is normal wear. Larger particles that can be felt between your fingers indicate problems with metal parts in drive.

If metal flakes appear on the magnet, take the boat to your Volvo Penta dealer.

Dispose of used oil and all oil soaked shop materials according to local laws and regulations.

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50400

8. Proper oil level is determined by filling drive until it appears at oil level hole beside shift mechanism. To access oil level hole, remove five screws securing shift cover.

9. Remove oil level plug from hole.

10. Check magnet for metal (see Step 7 above).

11. Check O-rings on both plugs and dipstick for wear or nicks. Replace if needed.

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50403

Maintenance

12. Fill drive with Volvo Penta Synthetic Gear Lubricant SAE 75W-90. Use a pump with 3/8-16 UNC threaded fitting to fill sterndrive through oil drain plug hole. Fill slowly to purge air. Sterndrive is properly filled when oil appears at the oil level plug hole.

NOTICE! Filling sterndrive too quickly may form air

pockets that will cause an inaccurate oil level reading. Running the sterndrive with improper oil level will result in serious internal sterndrive damage.

13. When oil is filled to oil level hole, install and hand tighten dipstick and oil level plug to prevent excessive oil loss when pump is removed from drain hole.

14. Remove pump, then quickly install oil drain plug. Hand tighten drain plug. Make sure O-rings are correctly installed and seated.

15. Check oil level with dipstick. Oil should show on flat portion F of the dipstick. If necessary, add oil through the dipstick hole. See Checking the Drive

Unit Lubricant (SX-A/DPS-A) on page 89.

50398

NOTICE! When washing the drive unit, do not use a

pressure washer. Using a pressure washer will damage the water intake hose and the drive bellows.

16. Tighten drain and oil level plugs to 62–89 in. lb. (7–10 Nm).

17. Tighten dipstick to 48–72 in. lb. (5.4–8.1 Nm).

18. Install shift cover and tighten screws to

14.8–20.7 ft. lb. (20–28 Nm).

19. Reinstall propellers. See Propeller Care on page 102.

20. If lubricant has been completely changed, oil level must be rechecked after unit has been briefly run to purge trapped air. Add oil through dipstick opening to bring oil up to proper level.

Alternate Fill Procedure (SX-A/DPS-A)

If you cannot fill drive unit through oil drain plug, you can fill it by triming the drive up five degrees and adding oil through the oil level plug. When oil is at the oil level plug hole, place the drive in down position, then reinstall the oil level plug.

Be prepared to catch any excess oil dripping out of oil level plug hole.

Check the oil level with the dipstick. Oil should show on the flat portion of the dipstick. Add oil if required, through the dipstick hole. See Checking the Drive Unit Lubricant (SX-A/DPS-A) on page 89.

This alternate fill method is slow and you must be careful not to trap air in the drive. The oil level must be rechecked after the unit has been briefly run to purge trapped air. Several cycles may be needed to obtain the proper oil level.

VPA 7748131 English 09-2007 91

Maintenance

Sterndrive Oil Capacity (SX-A/DPS-A)

All SX-A Models: 2.58 quarts (2.44 liters)

All DPS-A Models: 2.38 quarts (2.25 liters)

NOTICE! If your drive is equipped with a Drive Spac-

er, you will need to add more oil than the recommended amount. We urge you to check the oil level with the dipstick whenever you are changing or topping up the oil.

Pitot Tube (Speedometer Port)

The pitot tube, located at the leading edge of the lower unit, provides pressure input for the speedometer. If the pitot tube becomes clogged (e.g. the boat runs aground or the sterndrive drags through silt as the boat is loaded onto the trailer), the speedometer may stop functioning.

There are two methods for clearing debris from the pitot tube:

50641

Method 1

Use a six inch length of stiff wire of 1/8 in. (3 mm) thickness or a wire coat hanger to push any debris in the pitot tube into the drive cavity.

Method 2

Use compressed air to clear the pitot tube.

1. The pitot tube hose (A) is located at the transom shield, inside the boat and just behind the engine. Once you have located the pitot tube hose, remove the speedometer hose (C) from the plastic barb fitting (B).

2. Attach the hose from an air compressor to the barb fitting.

3. Have someone assist you by placing a rag in front of the pitot tube at the leading edge of the lower unit.

4. Blow air, pressurized to no more than 116 psi (800 kPa), into the pitot tube hose until your assistant can feel the air exiting the pitot tube.

CAUTION! Do not place bare hand(s) in front of the pitot tube to check for air flow as debris may be ejected forcefully enough to cause an injury.

NOTICE! Do not exceed 116 psi (800 kPa) as this

may damage the drive.

5. Reattach the speedometer hose to the barb fitting on the pitot tube hose.

92 VPA 7748131 English 09-2007

Drive Components (XDP-B)

The drive unit is filled at the factory with Volvo Penta Synthetic Gear Oil.

Drive Unit Lubrication (XDP-B)

Checking the Drive Unit Lubricant (XDP-B)

At each usage, check the oil level in the drive unit by inspecting the drive oil reservoir.

 Make sure that the oil level is below the

“FULL LINE” marking and above the “MIN” marking.

• The oil should be amber-colored.

• The oil will appear milky if any moisture is

present. You can check the oil’s appearance by removing the reservoir cap.

• No metal flakes should appear in the oil.

NOTICE! The drain plug C is magnetized. Any metal

flakes in the drive will generally attach to the

XDP02200

drain plug.

Maintenance

XDP01300

 If moisture or metal flakes appear in the drive

unit oil, take the boat to your Volvo Penta dealer.

 If the oil level is low, add only enough lubri-

cant to bring the oil level to just below the “FULL LINE” marking on the reservoir.

 You should completely drain and refill the

drive unit at least once per season.

Draining the Drive Unit (XDP-B)

1. Place the drive unit in the run (down) position.

2. Remove propellers and mounting hardware.

NOTICE! Special tools are required to remove the

Duoprop propellers.

3. Remove the two 10mm screws (1) securing the rear cover to access the oil vent plug.

4. Remove the oil drain plug C and the vent plug B.

5. Allow the drive unit to drain completely. Dispose of used oil according to applicable environmental regulations.

22854

VPA 7748131 English 09-2007 93

Maintenance

XDP02200

Filling the Drive Unit (XDP-B)

1. Remove the two 10mm screws (1) securing the rear cover to access the oil vent plug.

2. Fill the drive unit with Volvo Penta Synthetic Gear Oil. Fill through the oil drain plug location C. Fill slowly to purge air. The drive unit is properly filled when the oil appears at the oil vent hole A.

3. When filled to the proper level, install the oil vent plug, then the oil drain plug C.

4. Tighten oil vent and drain plugs securely.

5. Install the rear cover and tighten screws securely.

If you cannot fill the drive unit through the oil drain plug, you can fill the drive by trimming it up a few degrees and filling it through the oil vent hole. Reinstall the oil vent plug, and place the drive in the run (down) position. Remove the vent plug and check the oil level. Reinstall the vent plug and tighten securely.

NOTICE! If the drive unit was filled through the oil

vent hole, wait 15 minutes before checking oil. This will help ensure all air is purged from the oil cavity. Leave the oil vent plug loose during the waiting period.

6. Re-install the propellers. You may refer to the section entitled Propeller Care on page 102 for instructions on replacing the propeller.

7. Check the oil level at the drive oil reservoir. If necessary, add oil through the reservoir cap. Please refer to the section entitled Technical Data on page 115 for drive unit oil capacity.

NOTICE! When washing the drive unit, do not use a

pressure washer. Using a pressure washer will damage the water intake hose and the drive bellows.

94 VPA 7748131 English 09-2007

Volvo 5.7GiE300-J, 5.7GXiE-J, 5.7OSXiE-J, 8.1GiE-J, 8.1GXiE-J Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Welcome Aboard

Table of Contents

Safety Information

General Information

Safety Precautions (Maintenance and Service)

Knowledge

Engine Decals

Stop the Engine

Lifting the Engine

Before Starting the Engine

Washing the Engine

Fire and Explosion

Fuel and Lubrication Oil

Non-Original Components

Batteries

Start Spray

Hot Surfaces and Fluids

Cooling System

Fuel System

Lubrication System

Electrical System

Carbon Monoxide Poisoning

Chemicals

Safety Precautions While Operating the Boat

Your New Boat

Accidents

Maneuvering

Emergency Stop Switch

Daily Checklist

Refueling

Do not Start the Engine

“Station Wagon” Effect & Carbon Monoxide

Safety Checklists

Planning Your Trip

Trip Checklist

Safety Equipment

Safety Equipment Checklist

Replacement Parts and Tools Checklist

Basic Safety Rules of Boating

High Performance Boat Operation

Introduction

Care of the Environment

Fuel and Oils

Breaking-in

Certified Engines

Power Ratings

Load Condition (Speed of Planing Hull)

General Information

Warranty Information

Warranty Registration Form

Doing Your Own Maintenance and Repairs

Volvo Action Service (VAS)

Volvo Penta Dealer Network

Toll-free Dealer Locator Service

Volvo Penta on the Internet

Informational Decals and Identification Plates

Identification Numbers

Owner’s Identification Card

Service, Replacement Parts, and Accessories

Instrumentation

Instrument Panel

Audible Alarm

Emergency Stop Switch

Checking Instruments

Oil Pressure

Engine Coolant Temperature

Voltage/Charge

Power Trim/Tilt

Trim Instruments

Analog Trim Instrument

Trim/Tilt Motor Protection

Impact Protection

Engine Protection Mode

Engine Control Module (ECM)

Other Instruments

Controls