Volvo 4.3GXi-F, 4.3OSi-F, 5.0GXi-F, 5.0OSi-F, 5.7Gi-F User Manual
...
Workshop Manual
EGC Diagnostics
4.3GXi-F(F), 4.3OSi-F(F)
5.0GXi-F(F), 5.0OSi-F(F)
5.7Gi-F(F), 5.7GXi-G(F)
5.7OSi-E(F), 5.7OSXi-E(F)
8.1Gi-G(F), 8.1GXi-F(F), 8.1OSi-C(F)
C
2(0)
Copyright © 2006 Volvo Penta of the Americas, Inc. All rights reserved. This manual 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.
General Information . . . . . . . . . . . . . . . . . . . 1
System Description . . . . . . . . . . . . . . . . . . 29
Volvo Penta Diagnostic Scan Tool . . . . . . 35
Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 76
ECM Limits . . . . . . . . . . . . . . . . . . . . . . . . 305
Vodia Index by Number . . . . . . . . . . . . . . 310
VPA 7746872 English 2006-10
VPA 7746872 English 2006-10
Section 1: General Information
Intake Manifold Vacuum Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gasoline Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gasoline Containing Alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Off-Season Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Prepare a storage mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Change Motor Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 13
Change Sterndrive Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drain Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preparation for Boating After Storage . . . . . . . . . . . . . . . . . . . . 15
Engine Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Submerged Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Information
20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Positive Closed-Type Ventilation System . . . . . . . . . . . . . . . . . . 19
5.0L and 5.7L engines only . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting - System Isolation . . . . . . . . . . . . . . . . . . . . . . 20
Engine Troubleshooting Guides . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine Cranks, But Will Not Start . . . . . . . . . . . . . . . . . . . . . . 22
Hard Starting - Cold Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hard Starting - Hot Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Runs Rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Noises and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Dies Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Won’t Reach Operating RPM . . . . . . . . . . . . . . . . . . . 25
Defective Engine Lubricating System . . . . . . . . . . . . . . . . . . . 26
Low Battery Voltage After Short Storage . . . . . . . . . . . . . . . . 26
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
This service manual is divided into sections concerning various systems and assemblies. Refer to the Contents to locate the section covering the system or assembly requiring service. Each section title page
has an additional listing that will describe the sections contents in
more detail. Be sure to read the Safety Section at the end of this man-
ual, and pay special attention to all safety warnings as they appear
throughout the text. Since models are subject to change at any time,
some photos may not depict actual product.
VPA 7746872 English 2006-10 1
General Information
Good Service Practice Service required for the engine and sterndrive is generally one of three
kinds:
• Normal care and maintenance - which includes putting a new
engine and stern drive into operation, storing, lubrication, and
care under special operating conditions such as salt water and
cold weather.
• Operating malfunctions - due to improper engine or drive
mounting, propeller condition or size, boat condition, or the malfunction of some part of the engine. This includes engine servicing procedures to keep the engine in prime operating condition.
• Complete disassembly and overhaul - such as major service
or rebuilding a unit.
It is important to determine before disassembly just what the trouble is
and how to correct it quickly, with minimum expense to the owner.
When repairing an assembly, the most reliable way to ensure a good
job is to do a complete overhaul on that assembly, rather than just to
replace the bad part. Wear not readily apparent on other parts could
cause malfunction soon after the repair job. Repair kits and seal kits
contain all the parts needed to ensure a complete repair, to eliminate
guesswork, and to save time.
Repair time can also be minimized by the use of special tools. Volvo
Penta special tools are designed to perform service procedures
unique to the product that cannot be completed using tools from other
sources. They also speed repair work to help achieve service flat rate
times. In some cases, the use of substitute tools can damage the part.
Preparation for Service Proper preparation is extremely helpful for efficient service work. A
clean work area at the start of each job will minimize tools and parts
becoming misplaced. Clean an engine that is excessively dirty before
work starts. Cleaning will occasionally uncover trouble sources. Obtain
tools, instruments and parts needed for the job before work is started.
Interrupting a job to locate special tools or repair kits is a needless
delay.
Caution!
Use proper lifting and handling equipment. Working on
stern drives without proper equipment can cause damage
and personal injury.
Always use clean fresh fuel when testing engines. Troubles can often
be traced to the use of old or dirty fuel.
Service Policy It is a Volvo Penta policy to provide dealers with service knowledge so
they can give professional service demanded by today’s consumer.
The Volvo Penta Training Centers, frequent mailing of Service Bulletins, Letters and Promotions, Special Tools, Partner Network, and this
Service Manual represent the latest effort to assist dealers in giving
consumers the best and most prompt service possible. If a service
question does not appear to be answered in this manual, you are
invited to contact the Volvo Penta Service Department by calling or
through Partner Network for additional help. Always be sure to give
complete information, including engine model number and serial number.
2 VPA 7746872 English 2006-10
General Information
Replacement Parts Warning!
When replacement parts are required, always use genuine
Volvo Penta parts, or parts with equivalent characteristics, including type, strength, and material. Failure to do
so may result in product malfunction and possible injury
to the operator and/or passengers.
Parts Catalogs Parts Catalogs and the electronic parts catalog (EPC) contain
exploded views showing the correct assembly of all parts, as well as a
complete listing of the parts for replacement. These catalogs are helpful as a reference during disassembly and reassembly, and are available from Partner Network and Volvo Penta Parts.
Special Service Tools Volvo Penta has specially designed tools to simplify some of the disas-
sembly and assembly operations. These tools are illustrated in this
Service Manual, in many cases in actual use. All special tools can be
ordered from Volvo Penta Parts. Individual purchasers of Service
Manuals must order Special Tools through an authorized dealer.
Product References, Illustrations &
Specifications
Volvo Penta reserves the right to make changes at anytime, without
notice, in specifications and models and also to discontinue models.
The right is also reserved to change any specifications or parts at any
time without incurring any obligation to equip same on models manufactured prior to date of such change. All information, illustrations and
specifications contained in this manual are based on the latest product
information available at the time of printing. The right is reserved to
make changes at anytime without notice.
All photographs and illustrations used in this manual may not depict
actual models or equipment, but are intended as representative views
for reference only. The continuing accuracy of this manual cannot be
guaranteed.
The purpose of an engine tune-up is to restore power and performance that has been lost through wear, corrosion or deterioration of
one or more parts or components. In the normal operation of an
engine, these changes can take place gradually at a number of points,
so that it is seldom advisable to attempt an improvement in performance by correction of one or two items only. Time will be saved and
more lasting results will be obtained by following a definite and thorough procedure of analysis and correction of all items affecting power
and performance.
Economical, trouble-free operation can better be ensured if a complete
tune-up is performed once every year, preferably in the spring. Components that affect power and performance can be divided into three
groups:
• Components affecting compression
• Components affecting ignition
• Components affecting fuel system
Tuning the Engine Tune-up procedures should cover these groups in the order given.
While the items affecting compression and ignition may be handled
according to personal preference, correction of items in the fuel system group should not be attempted until all items affecting compres-
VPA 7746872 English 2006-10 3
General Information
Engine Compression Testing During all work done around the engine, while the engine is running or
sion and ignition have been satisfactorily corrected. Most of the
procedures for performing a complete engine tune-up will be covered
in greater detail in this manual. This section will deal mainly with the
order of procedures involved in tuning the engine.
being cranked, use extreme care to avoid getting fingers or clothing
caught in any belts, pulleys, or other moving parts.
2. Visually inspect stern drive unit for leaks, missing parts or other
obvious defects. Replace deteriorated parts.
3. Compression check: Proper compression is essential for good
engine performance. An engine with low or uneven compression
cannot be properly tuned.
• Operate engine to normal operating temperature.
Caution!
Engine must not be started and run without water for cooling.
• Remove any foreign matter from around spark plugs by blowing
out with compressed air.
• Remove and inspect all spark plugs. Install thread-type compression gauge in spark plug hole.
• Set the Volvo Penta Scan tool to “ECM TESTS” and select
“COMPRESSION TEST” before cranking the engine.
Caution!
This test commands the ECM to disable all spark and fuel
injector outputs. The test must be properly exited from the
Scan Tool to re-enable normal spark and fuel operation.
DO NOT perfrom this test in open water. Always perform
this test dockside or on a trailer. The engine will be disabled until the test is properly exited.
If the scan tool is disconnected during the COMPRESSION TEST, the engine will remain disabled until the scan
tool is reconnected and the COMPRESSION TEST mode is
exited properly. Refer to the documentation that comes
with the Scan tool for further information on Scan tool
operation.
Test Conclusion The indicated compression pressures are considered normal if the
lowest reading cylinder is within 75% of the highest.
Example:
If the highest pressure reading was 140 PSI, 75% of 140 is 105.
Therefore, any cylinder reading less than 105 PSI indicates an improperly seated valve, worn valve guides, piston, cylinder, or worn or broken piston rings. Any cylinder reading 105 PSI or greater is within
specifications, and compression is considered normal.
4 VPA 7746872 English 2006-10
General Information
If one or more cylinders read low, squirt approximately one tablespoon
of engine oil on top of the pistons in the low reading cylinders. Repeat
compression pressure check on the cylinders.
1. If compression improves considerably, the piston rings are at fault.
2. If compression does not improve, valves are sticking or seating
poorly, or valve guides are worn.
3. If two adjacent cylinders indicate low compression pressures and
squirting oil on the pistons does not increase the compression, the
cause may be a cylinder head gasket leak between the cylinders.
This problem could allow engine oil and/or coolant to enter the cylinders. It is recommended the following quick reference chart be
used when checking cylinder compression pressures. The chart
has been calculated so that the lowest reading number is 75% of
the highest reading.
Table 1: Compression Pressure Limit
Max. PSI Min. PSI Max. PSI Min. PSI Max. PSI Min. PSI Max. PSI Min. PSI
134 101 154 115 174 131 194 145
136 102 156 117 176 132 196 147
138 104 158 118 178 133 196 148
140 105 160 120 180 135 200 150
142 107 162 121 182 136 202 151
144 108 164 123 184 138 204 153
146 110 166 124 186 140 206 154
148 111 168 126 188 141 208 156
150 113 170 127 190 142 210 157
152 114 172 129 192 144 212 158
After checking cylinder compression, repairs should be made as necessary. Subsequent adjustments to an engine that does not have
proper compression will not measurably improve performance or correct operational problems. After verifying compression, check ignition
and fuel system components.
Ignition System Components •Spark Plugs
• Spark Plug Leads
• Distributor Cap
• Rotor
• Ignition Coil
• High Tension Lead
• Ignition Switch
• Circuit Wiring and Connectors
Fuel System Components • Fuel Tank Pickup and Screen
VPA 7746872 English 2006-10 5
General Information
• Fuel Tank Vent
• Anti-Siphon Valve (if equipped)
• Fuel Octane and Quality
• Boat Fuel Lines and Valves
• External Engine Fuel Filter
• Fuel Pump(s) and Line
• Engine PCV Valve
• Flame Arrestor
All of the above listed components are not necessarily part of an
engine tune-up, but must be considered when attempting to correct
engine/boat performance problems. Repair or replace components
only as required.
Warning!
Do not substitute automotive parts. Volvo Penta marine
components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta
marine components are specially designed not to cause
ignition of fuel vapors in the bilge or engine compartment.
The use of automotive parts can result in fire and explosion.
Intake Manifold Vacuum Testing
Test Procedures 1. Install a vacuum gauge to a good intake manifold source (usually
2. Observe the vacuum gauge while operating the engine over a
Test Results
1. A steady vacuum reading between 14 and 19in. Hg. (47-64 kPa)
2. A vacuum reading below 14 in. Hg. (47 kPa) at idle, indicates an
3. Possible causes of low intake manifold vacuum are late ignition
4. If the gauge fluctuates at idle, possible causes are sticking or leak-
5. If the gauge fluctuates at idle but smooths out as engine RPM
6. If the gauge fluctuates more with increases engine RPM, check for
7. If the vacuum gauge fluctuates regularly with each engine cycle,
at the PCV valve port), following the gauge manufacturer’s instructions. Start and warm up the engine.
range of engine speeds.
at idle indicates an engine in good mechanical condition.
engine that is not developing enough vacuum. Further testing for
base mechanical problems is needed.
timing, low compression, poor engine sealing, leaks at vacuum
lines and connections or bad MAP sensor.
ing valves, or an ignition miss.
increases, check for bad valves or camshaft.
weak or broken valve springs, bad valves, ignition miss, or a leaking head gasket.
check for a bad valve.
6 VPA 7746872 English 2006-10
General Information
10
15
10
15
30
15
30
10
15
25
30
10
10
15
30
15
25
10
25
15
20
30
15
20
30
30
20
25
10
25
30
10
O
8. If the vacuum reading drops steadily as engine RPM increases,
check the exhaust system between the engine and vertical drive
for restrictions.
9. See table and chart below and on the following page for more
information.
15
10
5
0
10
5
0
20
25
30
In./Hg.
15
20
25
30
In./Hg.
15
10
5
0
10
5
0
20
25
30
In./Hg.
15
20
25
30
In./Hg.
15
10
5
0
10
5
0
20
25
30
In./Hg.
15
20
25
30
In./Hg.
15
10
5
0
10
5
0
20
25
30
In./Hg.
15
20
25
30
In./Hg.
FGH I
15
10
5
0
20
25
30
In./Hg.
15
10
5
0
20
25
30
In./Hg.
15
10
5
0
20
25
30
In./Hg.
15
10
5
0
20
25
30
In./Hg.
15
10
5
0
20
25
30
In./Hg.
EABCD
15
10
5
0
20
25
30
In./Hg.
J
15
10
5
0
20
25
30
In./Hg.
K
Pos Condition Reading
A Normal at Idle 14-19 in. Hg. (47-64 kPa)
B Late Ignition Timing 11-17 in. Hg. (37-57 kPa)
C Late Valve Timing 8-15 in. Hg. (27-50 kPa).
L
MN
D Intake Leak Low but steady reading
E Normal Acceleration Drops to 2 then rises to 25 when throttle is rapidly increased and
decreased.
F Worn Rings Drops to 0, then rises to 22 when throttle is rapidly increased and
decreased
G Sticking Valve(s) Normally steady, intermittently flicks downward approx. 4 in. Hg. (13 kPa)
from highest level.
H Leaking Valve Drops 2 in. Hg. (6 kPa) from highest reading.
I Burned or Warped Valve Evenly spaced down-scale flicker approximately 5 in. Hg (17 kPa).
J Worn Valve Oscillates Approximately 4 in. Hg. (13 kPa).
K Weak Valve Springs Violent oscillations as RPM increases.
L Improper Idle Mixture Floats slowly between 13-17 in. Hg. (44-57 kPa)
M Restricted Exhaust Normal when first started. Drops to approx. 0 as RPM increases
N Head Gasket Leak Floats between 5-20 in. Hg. (17-68 kPa)
O Defective Ignition Component Slight float between 14-16 in. Hg. (47-54 kPa)
VPA 7746872 English 2006-10 7
General Information
Gasoline Requirements
DANGER!
Gasoline is extremely flammable and highly explosive
under certain conditions. Always stop engine and do not
smoke or allow open flames or sparks near the boat when
refuelling gas tanks. 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 which could cause sparks and ignite fuel
vapors.
USE ONLY UNLEADED FUEL. Use lead-free gasoline with the fol-
lowing 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.
Premium fuels contain injector cleaners and other additives that protect the fuel system and provide optimum performance.
Gasoline Containing Alcohol
Caution!
Engine damage resulting from the use of gasoline with
octane 86 AKI (89 RON) and lower is considered misuse of
the engine and will void the engine warranty. Vol vo Pe nta
suggests the use of 89 AKI or higher fuels. These fuels
have additives that are beneficial to maximum engine performance and long life of service components.
To prevent gum formation and corrosion in the fuel system, use a
Marine Fuel Stabilizer in the gasoline.
Many brands of gasoline being sold today contain alcohol. Two commonly used alcohol additives are Ethanol (ethyl alcohol) and Methanol
(methyl alcohol).
Caution!
Do not use any gasoline which contains Methanol (methyl
alcohol).
See the boat’s Operators Manual to determine if the boats fuel system
is compatible with alcohol blended fuels. If it is, your engine may use
gasoline blended with no more than 10% Ethanol (ethyl alcohol) meeting the minimum octane specification. Do not use any gasoline which
contains METHANOL (methyl alcohol).
Continued use of METHANOL (methyl alcohol) fuel will cause serious
damage to the fuel system.
If you use gasoline containing alcohol, be aware of the following:
8 VPA 7746872 English 2006-10
Crankcase Oil
General Information
• ïThe engine will operate leaner. This may cause engine problems such as vapor lock, low speed stalling, or hard starting.
• ïAlcohol blended fuels attract and hold moisture. Moisture can
cause fuel tank corrosion. Inspect fuel tanks at least annually.
Replace corroded or leaking fuel tanks.
• ïFrequently inspect non-metallic parts of fuel system and
replace if excessively stiff, deteriorated or leaking.
Fuel leakage can contribute to a fire and/or explosion.
Initial factory fill is a high quality motor oil for API Service SJ. 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 in the safe range between the Add and Full
marks on the dipstick. This range represents approximately 1 litre (1
quart). If it is necessary to add or change the motor oil, use a quality oil
with API service category SJ.
At the end of the break-in period (20 hours), change the crankcase oil
and replace the oil filter. Refer to Lubrication and Inspection Chart
for recommended oil change intervals.
Draining and Filling the Engine
Crankcase
NOTE! The use of multi-viscosity oils, such as 10W-30 or 10W-40,
is not recommended.
If using Volvo Penta Premium Synthetic Engine Oil, drain and refill
crankcase every 200 hours of operation or once a year, whichever occurs first.
If using oil other than Volvo Penta Premium Synthetic Engine Oil, drain
and refill crankcase every 100 hours of operation or once a year, whichever occurs first.
DANGER!
To prevent fire and explosion, always make sure engine
compartment is free of gasoline fumes before using any
spark-producing tools such as the electric drill motor
used with oil withdrawal pump kit.
Check the motor oil level frequently with the dipstick. When oil is to be
changed, remove dipstick and withdraw oil from crankcase through
withdrawal/dipstick tube. The oil withdrawal tube is provided so oil does
not have to be drained into the bilge. Withdraw oil with a suction pump.
Fill the crankcase to the specified capacity with a quality motor oil labelled for service category SH. When changing motor oil, select from
the following chart the SAE viscosity that matches the temperature
range in which the boat will be operated. If it is necessary to add motor
VPA 7746872 English 2006-10 9
General Information
oil, use motor oil of the same viscosity.
Table 2: Temperature Viscosity Recommendations
If the lowest Anticipated
Temperature is:
32° F (0° C) and above SAE 30
0° F (-18° C) to 32° F (0° C) SAE 20W-20
Below 0° F (-18° C) SAE 10
NOTE! Disregard any reference to multi-viscosity oil printed on
engine. Such reference is intended for automotive use
only and not marine application.
Caution!
Do not fill above full mark. Overfilling results in high operating temperatures, foaming (air in oil), loss of power, and
overall reduced engine life.
Table 3: Crankcase Capacities
Model With Filter
4.3GXi/OSi 5.0 qts. (4.7 liters)
The Following SAE Viscosity
Oils are Recommended
Sterndrive
Off-Season Storage
5.0GXi/OSi 5.5 qts. (5.2 liters)
5.7Gi/GXi/OSi/OSXi 5.5 qts. (5.2 liters)
8.1Gi/GXi 9.0 qts. (8.5 liters)
Inboards
5.7GiI/GXiI 5.5 qts. (5.2 liters)
8.1GiI/GXiI 9.0 qts. (8.5 liters)
Oil Filter Replace the oil filter whenever the motor oil is changed. This filter is a
self-contained, screw-on type. To remove, unscrew filter canister
counterclockwise and discard. When attaching a new filter, be sure the
gasket is lightly lubricated with motor oil. Hand tighten only, run engine
and check for leaks. Do not run engine without supplying cooling
water. See Parts Catalog for model and filter requirements.
Maintain the level with Volvo Penta Power Trim/Tilt & Steering Fluid.
Approved power steering fluids such as GM power steering fluid or
Dexron II automatic transmission fluid can also be used. Do not overfill
the pump reservoir.
There are nine steps that must be completed for Off-Season Storage
Preparation
10 VPA 7746872 English 2006-10
General Information
When gasoline engines are removed from service for long periods (2
months or more), it is important that they are correctly stored or protected (internally). Today’s gasoline blends are not as stable as in the
past and consideration must be given if the fuel will not be used within
a short time or if the engine is being placed in storage. Failure to properly stabilize the fuel can damage fuel system components and is not
considered as warrantable.
Boat manufacturers should follow the gasoline storage mixture
section for testing prior to shipment.
Note! Volvo Penta has discontinued the fuel stabilizer #3855832,
a suitable replacement can be purchased locally at most
automotive supply stores.
Limited Use If the vessels fuel within the tank(s) will not be consumed within a 30-
day period from the time of filling, a gasoline fuel stabilizer must be
added as per the manufacturers instructions. This will help prevent the
fuel from breaking down and causing reduced engine performance or
damage from uncontrolled combustion.
Storage If the boat is being placed into storage, a gasoline fuel stabilizer must
be added to the tank(s) as per the manufacturers instructions. The
amount of stabilizer required is determined by the quantity of fuel and
the length of time it will be placed in storage. The maximum period that
fuel can be stabilized is six months due to limitations of the stabilizers
and fuels.
DANGER!
Any fuel leakage should be corrected immediately to prevent possible fire and/or explosion.
Caution!
Do not run engine out of fuel or run the electric fuel
pumps dry more than 10 seconds. Running the electric
fuel pumps dry will cause fuel pump damage.
Prepare a storage mixture In addition to stabilization of the fuel, it is highly desirable to have the
valves and cylinders coated with a light film of oil previously accomplished through fogging. Today’s fuel injection manifolds are designed
with a complex air channel design that will not allow the traditional fogging oils to be injected past the throttle plate while running. The oil will
get stuck in the plenum and never reach the cylinders. Together with
the stabilizer, two-cycle motor oil can be added to a fuel mixture for
stabilization purposes.
• Using an outboard motor six-gallon fuel tank, add two-cycle
motor oil at a ratio of 50:1 (one pint to 6 gallons) and stabilizer
at one ounce per gallon (unless stated otherwise on the manufacturers label). Mix well.
• Disconnect boat fuel line at engine fuel pump. Attach the storage mixture fuel tank.
• Connect a suitable engine flush device if the boat is not in the
water.
VPA 7746872 English 2006-10 11
General Information
Electric Fuel Pumps and Fuel Cells Regardless of the ratio of fuel stabilizer to fuel we use, the maximum
• Run the engine on the storage mixture for approximately 5 minutes at 1500 RPM. This will ensure that all fuel system and
internal engine components are thoroughly protected. Do not
operate the engine above 1500 RPM as the water pump
demand may exceed the supply, damaging the pump.
• Reduce the engine speed to idle and stop the engine.
• Reconnect the fuel fitting and check for fuel leaks.
recommended storage time for gasoline, according to STA-BIL, is six
months. During final assembly testing at our Lexington factory, each
engine is run on a fuel mix that is stabilized. Each engine is shut off
without running the fuel pumps dry and the fuel system is sealed to
prevent damage. With the delay in time between the product getting
installed in a boat, shipped to you, sold and finally delivered; the sixmonth time frame can easily be exceeded.
Since delivering a quality, dependable product is one of our highest
goals; we work closely with our suppliers to identify the root cause of
failure on any parts returned for warranty credit. While there are certainly legitimate failures of fuel pumps, the major portion of them are
returned to us due to varnished fuel from long term storage. We would
like to offer some advice on dealing with these issues.
Stuck Pumps If a fuel pump appears stuck and will not operate, you may try briefly
reversing the polarity to the pump to turn it in the opposite direction.
You should disconnect the electrical plug of one pump at a time on the
fuel cell to determine which pump might have a problem.
Noisy Fuel Pumps Electric pumps will often cavitate and become noisy if they are starving
for fuel. On carbureted engines or low-pressure fuel cell pumps, check
the fuel supply, quality of the fuel hose, anti-siphon valve, and filter
before replacing the fuel pump.
A noisy high-pressure pump on a fuel cell may indicate a low fuel level
in the reservoir. Check the fuel supply and low pressure pump operation to be sure the reservoir is receiving the correct volume of fuel. The
same information would apply to engines with the earlier vapor separator tank design.
This information may help prevent the needless replacement of pumps
in many cases and reduce the repair time for the boat owner.
Change Motor Oil and Oil Filter • Engine should first be operated under load until oil is thoroughly
warmed up. If oil is allowed to warm up before draining, a more
complete draining will be accomplished. In addition, accumulated impurities will be held in suspension by the oil and be
removed during draining operation.
• Remove motor oil by siphoning it out of oil withdrawal tube. Follow the procedure under Draining and Filling the Engine
Crankcase.
• Install a new oil filter and fill crankcase with recommended oil.
Caution!
12 VPA 7746872 English 2006-10
Change Sterndrive Lubricant
Drain Cooling System
D
C
A
B
23681
General Information
Sterndrive must be submerged in water or an accessory
flushing adaptor must be used while operating engine.
When using a flushing adaptor, remove propeller before
starting engine to prevent accidental contact with rotating
propeller.
• With sterndrive in full down position, run engine at a fast idle for
a few minutes to distribute clean oil through engine.
• Shut off engine and check oil level. Check oil filter gasket for
leaks. Add oil if necessary to bring oil level up to, but not over,
the full mark.
Drain and refill with fresh Volvo Penta GL-5 Synthetic Gear Lubricant
or Mobilube 1 SHC Fully Synthetic SAE 75W-90 (meeting or exceeding MIL-L-2105C or D, API GL-4 or 5) gear lubricant. Refer to Vertical
Drive Service Manual.
When draining the cooling system, raise or lower the bow of the boat
to position the engine in a level horizontal plane. This will provide complete drainage of the engine block and manifolds. If the bow is higher
or lower that the stern, some water may be trapped in the engine block
or manifolds.
Improper or incomplete draining may result in freeze damage to the
engine, manifolds, sterndrive, or other components. Freeze damage is
not covered under Volvo Penta’s Limited Warranty.
4.3GXi, 4.3OSi
Front
Port
1. Remove inlet (A) and outlet (B) hoses from raw water pump and
rotate engine with starter 1-2 revolutions. If engine starts to run,
shut off immediately.
Caution!
Do not run engine without water. If engine starts with the
water intake hose disconnected, shut off immediately.
Allowing the engine to run without water will damage the
engine and cooling components.
2. Disconnect the small water by-pass hose at the top of the thermo-
stat housing.
3. Disconnect and drain large hose at the circulation pump.
4. Disconnect the fuel cell water discharge hose. Lower the hose into
the bilge to allow draining. Blow out and remaining water with
compressed air. Reconnect after draining is complete.
5. Remove cylinder block drain plug. Clear hole with small wire to
ensure complete drainage.
6. Remove exhaust manifold drain plug. Clear hole with small wire to
ensure complete drainage.
VPA 7746872 English 2006-10 13
General Information
Starboard 7. Remove cylinder block drain plug. Clear hole with small wire to
ensure complete drainage.
8. Remove exhaust manifold drain plug. Clear hole with small wire to
ensure complete drainage.
9. Reinstall drain plugs after draining is complete to keep the threads
of the drain holes from corroding. It will be difficult to install the
drain plugs if the plugs are left out over the winter.
5.0GXi, 5.0OSi, 5.7Gi, 5.7OSi, 5.7GXi, 5.7OSXi, 5.7GiI-F, 5.7GXiI-G
Front
Port
Starboard
1. Remove inlet (A) and outlet (B) hoses from raw water pump and
rotate engine with starter 1-2 revolutions. If engine starts to run,
shut off immediately.
Caution!
Do not run engine without water. If engine starts with the
water intake hose disconnected, shut off immediately.
Allowing the engine to run without water will damage the
engine and cooling components.
2. Disconnect and drain large hose at the circulation pump.
1. Remove cylinder block drain plug. Clear hole with small wire to
ensure complete drainage.
2. Remove exhaust manifold drain plug located at the rear of the
exhaust manifold. Clear hole with small wire to ensure complete
drainage.
1. Remove cylinder block drain plug. Clear hole with small wire to
ensure complete drainage.
2. Remove exhaust manifold drain plug located at the rear of the
exhaust manifold. Clear hole with small wire to ensure complete
drainage.
3. Reinstall drain plugs after draining is complete to keep the threads
of the drain holes from corroding. It will be difficult to install the
drain plugs if the plugs are left out over the winter.
8.1Gi, 8.1GXi, 8.1OSi, 8.1GiI-G, 8.1GXiI-F
Front
1. Remove inlet (A) and outlet (B) hoses from raw water pump and
rotate engine with starter 1-2 revolutions. If engine starts to run,
shut off immediately.
Caution!
Do not run engine without water. If engine starts with
intake hose disconnected, shut off immediately. Allowing
the engine to run without water will damage the engine
and cooling components.
2. Disconnect and drain large hose at the circulation pump.
Port
1. Remove cylinder block drain plug. Clear hole with small wire to
ensure complete drainage.
14 VPA 7746872 English 2006-10
General Information
2. Remove exhaust manifold drain plug located at the front of the
port exhaust manifold, behind the power steering pump. Clear
hole with small wire to ensure complete drainage.
Starboard
1. Remove cylinder block drain plug. Clear hole with small wire to
ensure complete drainage.
2. Remove exhaust manifold drain plug located at the rear of the
exhaust manifold. Clear hole with small wire to ensure complete
drainage.
3. Reinstall drain plugs after draining is complete to keep the threads
of the drain holes from corroding. It will be difficult to install the
drain plugs if the plugs are left out over the winter.
Preparation for Boating After Storage
1. Install all drain plugs if they were left out during storage. Install
cooling hoses and clamps. Check condition of hoses, manifold
end caps and clamps. Connect hoses to engine and tighten
clamps securely. Install boat drain plug, if removed.
2. Remove the distributor cap and rotor. Wipe the inside of the dis-
tributor cap dry with a clean cloth and spray with Corrosion Spray.
Replace the rotor and cap.
3. Clean the battery terminals. With the ignition switch in the "OFF"
position, install the battery and attach the battery cables. Spray
terminals with Corrosion Spray.
4. Open the fuel shut-off valve (if so equipped) and check all fuel
line connections for leaks.
5. Check the flame arrestor and clean if necessary. Reinstall, make
sure all parts are in place and tighten nut securely.
Warning!
Do not place fingers in the throttle body on electronic
throttle equipped engines. The throttle plate has a powerful motor that can cause severe injury if the ignition energized.
6. Make a thorough check of the boat and engine for loose or miss-
ing nuts and screws. Pump the bilge dry and air out the engine
compartment.
Danger!
To prevent a possible explosion, operate the blower as
recommended by the boat manufacturer before starting
engine. If the boat is not equipped with a bilge blower,
open engine cover or hatch prior to starting and leave
open until after engine is running.
If operating boat in water, tie boat securely to dock to prevent forward or backward movement.
When using a flushing adaptor, remove the propeller
before starting engine to prevent accidental contact with
rotating propeller.
VPA 7746872 English 2006-10 15
General Information
Engine Break-in
7. Test run engine: Launch boat or use a flushing adaptor installed
on Sterndrive.
Caution!
Do not start engine out of water unless using a flushing
adaptor. Always turn water on before starting engine.
Control water pressure as full water pressure may cause
damage to supply pump and engine.
8. With engine compartment open, start the engine. Monitor the volt-
meter, oil pressure and water temperature gauges frequently to be
sure all systems are operating properly. Check for fuel, oil, and
water leaks.
All engines have been run for a short period of time as 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.
NOTE!
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.
First Two Hours For the first five to ten minutes of operation, operate engine at a fast
idle (above 1500 RPM). After engine has reached operating temperature, momentarily reduce engine speed, then increase engine speed,
to assist break-in of piston rings and bearings.
During the remaining first two hours of operation, accelerate boat onto
plane quickly and bring throttle back to maintain a planing attitude.
During this period, vary the engine speed frequently by accelerating to
approximately three-fourths throttle for two to three minutes, then back
to minimum planing speed. Maintain planing attitude to avoid excessive engine load.
DO NOT RUN ENGINE AT A CONSTANT RPM FOR PROLONGED
PERIODS OF TIME DURING THE BREAK-IN PERIOD.
Next Eight Hours During next eight hours, continue to operate at approximately three-
fourths throttle or less (minimum planing speed). Occasionally reduce
throttle to idle speed for a cooling period. During this eight hours of
operation it is permissible to operate at full throttle for periods of less
than two minutes.
DO NOT RUN ENGINE AT A CONSTANT RPM FOR PROLONGED
PERIODS OF TIME DURING THE BREAK-IN PERIOD.
Final Ten Hours During the final ten hours of break-in, after warming engine to operat-
ing temperature, it is permissible to operate at full throttle for five to ten
minutes at a time. Momentarily reduce then increase engine speed to
assist break-in of rings and bearings. Occasionally reduce engine
speed to idle to provide cooling periods.
DO NOT RUN ENGINE AT A CONSTANT RPM FOR PROLONGED
PERIODS OF TIME DURING THE BREAK-IN PERIOD.
16 VPA 7746872 English 2006-10
General Information
During break-in period, be particularly observant during initial running
of engine, as follows:
1. Check crankcase oil level frequently. Maintain oil level in safe
range, between “add” and “full” marks on dipstick.
NOTE! If you have a problem getting a good oil level reading on
dipstick, rotate dipstick 180° in tube.
2. Watch oil pressure gauge. If indicator fluctuates whenever boat
attitude (i.e. turning, climbing on plane, etc.) is changed, it may be
the oil pickup screen is not covered with oil. Check crankcase dipstick, and add oil to crankcase if required. DO NOT OVERFILL. If
oil level is correct and condition still exists, check for possible
gauge or oil pump malfunction.
NOTE! 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.
3. Watch engine temperature indicator to be sure there is proper
water circulation.
Caution
Failure to follow the break-in procedure will void the
engine warranty.
At end of break-in period (20 hours), change the motor oil and replace
oil filter. Fill crankcase with recommended motor oil, See “Crankcase
Oil” on page 9.
Operation After Break-in After break-in, the engine can be operated at any RPM from idle to full
throttle. However, cruising at 3600 RPM or less saves fuel, reduces
noise, and prolongs engine life.
When starting a cold engine, always allow engine to warm up gradually. Never run engine at full throttle until engine is thoroughly warmed
up. Be sure to check oil level frequently during the first 50 hours of
operation, since oil consumption will be high until piston rings are
properly seated.
Submerged Engine Remove engine from water as quickly as possible.
It is imperative that all water is removed from the engine and immediately lubricate all internal parts. All electrical devices must also be
dried and inspected for water damage. Delay in completing these
actions may allow extensive engine damage.
Frequently check engine compartment for gasoline fumes and excessive water accumulation; water depth in bilge should be kept well
below flywheel housing.
20-Hour Check
1. Change engine oil and oil filter.
2. Check power trim/tilt reservoir for proper fluid level.
3. Change fuel filter/water separator.
4. Check flame arrestor for proper mounting, cleanliness or damage.
5. Start engine and check complete fuel system for leaks.
VPA 7746872 English 2006-10 17
General Information
3
8
6
0
0
9
1
6. Lubricate steering cable ram with Volvo Penta grease. Check
power steering pump reservoir for correct fluid level on models
equipped with power steering. Failure to properly lubricate the
steering system could lead to loss of steering control.
7. Check shift system for proper adjustment and operation.
8. Inspect exhaust system. Tighten all hose clamps, and check for
leaks.
9. Check tension on all drive belts.
10. Check all engine mount screws for tightness.
11. Check for any deficiencies, malfunctions, signs of abuse, etc. Cor-
rection of any problems at this time will prevent the worsening of a
minor problem and help ensure a trouble-free boating season.
12. Check oil level in Sterndrive and add as necessary with GL-5 Syn-
thetic Gear Lubricant or Mobilube 1 SHC Fully Synthetic SAE
75W-90 (meeting or exceeding MIL-L-2105C or D, API GL-4 or 5)
gear lubricant.
13. Make sure engine can achieve maximum rated RPM. See engine
specifications.
Belt Tension
22902 Serpentine belts are tensioned automatically and do not require
adjustment. Replace when the tension indicator lines up with the single line on the housing (A).
The Volvo Penta serpentine belts are for heavy-duty marine use. DO
NOT replace with automotive belts.
A
B
Positive Closed-Type Ventilation System
5.0L and 5.7L engines only A malfunctioning closed crankcase ventilation system may be indi-
cated by loping or rough engine idle. Do not attempt to compensate for
this idle condition by disconnecting the crank-case ventilation system
and making adjustments. The removal of the crankcase ventilation
system from the engine will adversely affect fuel economy and engine
18 VPA 7746872 English 2006-10
General Information
ventilation with resultant shortening of engine life. To determine
whether loping or rough idle condition is caused by a malfunctioning
crankcase ventilation system, perform the following tests.
NOTE! 8.1 engines have an internal crankcase ventilation system
and have no serviceable components.
NOTE! 4.3 engines do not have a PCV valve. The crankcase venti-
lation is provided by a fixed orifice located in the port
valve cover and connected by a hose to the intake manifold.
With Engine Idling
With Engine Stopped Remove PCV valve from its mounting and shake it. A metallic clicking
Servicing PCV Valve Caution!
1. Remove PCV valve from its mounting, but leave vacuum inlet side
connected to hose. If the valve is functioning properly and not
plugged, a hissing noise will be heard as air passes through valve.
A strong vacuum will be felt when a finger is placed over valve
inlet. Check for vacuum leaks in hose line and at all connections.
2. Reinstall PCV valve, then remove crankcase air inlet hose at
flame arrestor connection. Loosely hold a small piece of stiff paper
(such as a 3 x 5 memo card or parts tag card) over opening at end
of inlet hose. After a minute or so, (to allow crankcase pressure to
lower) the piece of paper should be sucked against hose opening
with a noticeable force.
noise should be heard, indicating that valve parts are free, and not
sticking.
If ventilation system passes these two tests, it can be considered functionally OK, and no further service is required. If it fails either test,
replace PCV valve and repeat Engine Idling Test.
If system still does not pass test, clean ventilation system hoses and
all passages to induction system in accordance with established procedures.
Do not attempt to clean crankcase ventilation regulator
valve. It should be replaced.
Clean crankcase ventilation system connection(s) on intake manifold
by probing with a flexible wire or bottle brush. Clean hoses, tubes and
associated hardware with a low-volatility, petroleum-base solvent and
dry with compressed air.
Troubleshooting - System Isolation
The following is to help you isolate a malfunction of one or possibly
several systems. After determining which systems are related to the
VPA 7746872 English 2006-10 19
General Information
Engine Does not Start
malfunction, refer to the individual system troubleshooting charts to
isolate the specific cause.
Engine should crank at specified RPM. If not, check for
1. Discharged or dead Battery
Cranking System
2. Loose or corroded connections
3. Cranking System Troubleshooting Chart in the Elec-
trical Ignition/ Fuel Service Manual
Ignition System Must have good spark at spark plugs. If not, check the:
1. Distributor Cap
2. Coil and spark plug leads
3. Ignition timing
4. Automatic spark advance
5. Appropriate Ignition Troubleshooting Chart in the
Electrical/Ignition/Fuel Service Manual.
Fuel System
1. Fuel Tank, valves, and lines
2. Fuel pump and filter
3. Boat Fuel System Troubleshooting Chart
4. Engine Fuel System Troubleshooting Chart
Engine Runs Improperly Check the following:
1. Compression
2. Ignition system
3. Fuel and injection system
4. Lubrication system
5. Cooling System
6. Sterndrive and propeller
7. PCV Valve
8. Engine Troubleshooting Guides
Engine Troubleshooting Guides
These guides were written to help you trace the symptoms of the trouble to the source, without having to read through and prove every possibility. Much of the information here will be familiar to well informed
mechanics.
Also, many factors will seem insignificant but when you think of it, usually the toughest problem to troubleshoot is caused by the smallest
error. The greatest aid to solving a service problem is information.
Start gathering information from the boat operator and write it on his
job card or work ticket. Find out pertinent facts, such as:
• When did this trouble start?
• How was the boat loaded?
• Did the trouble occur suddenly, or start gradually?
Analyze this information and try to match it to similar situations you
have experienced in the past. Keep in mind the fundamental rules:
20 VPA 7746872 English 2006-10
General Information
• COMPRESSION - Mixture inducted into cylinder and compressed.
• SPARK - Proper intensity at the proper time.
• FUEL - Proper mixture of air and fuel.
These are very old rules, but necessary for the engine to run. Use
these charts and the service information they refer to. Do not try to
remember tolerances, settings, measurements, etc., as they are written in the service manual. Leave your mind free to analyze the problem.
Following is a list of the troubleshooting guides which may be found on
the pages indicated.
Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
Engine Cranks, But Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
Hard Starting - Cold Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Hard Starting - Hot Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Engine Runs Rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23
Engine Will Not Crank
Starter Circuit - Check: • Battery condition: weak, dead, sulfated, bad cells
Engine Noises and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23
Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Engine Dies Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Engine Won’t Reach Operating RPM . . . . . . . . . . . . . . . . . . . . . . . . . page 25
Defective Engine Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . page 25
Low Battery Voltage After Short Storage. . . . . . . . . . . . . . . . . . . . . . . page 26
• Battery cables for loose or corroded connections
• Shorted or open ignition switch
• Starter motor and solenoid for shorts, grounds or open circuits
• Starter assist solenoid/starter relay
• Circuit breakers
• Wiring from battery to ignition switch
•See Electrical/Ignition/Fuel Service Manual
Engine Cranks, But Will Not Start
Ignition Circuit - Check: • Primary circuit wiring from ignition switch to ignition coil/ignition
module
• Secondary circuit wiring from coil to spark plug
• Spark plugs for proper gap, fouling, burned electrodes, cracked
or dirty insulator
•See Electrical/Ignition/Fuel Service Manual
• Low battery voltage
VPA 7746872 English 2006-10 21
General Information
Fuel System - Check: • Quantity and condition of fuel in boat tank
Cylinder Compression - Check • Conduct test following procedure in this section, and compare
Hard Starting - Cold Engine
• Operation and flow capacity of boat anti-siphon valve
• Fuel tank vent is unrestricted
• Fuel tank pick-up screen is clean
• Correct diameter/unrestricted boat fuel lines
• Fuel shutoff and multiple tank valves are open and operating
properly
• Fuel pump vent hose for signs of fuel or oil that would indicate a
fuel pump failure.
• Fuel pump/relay/circuit breaker operation
• External fuel filter
• See Electrical/Ignition/Fuel System Service Manual
readings to Compression Limit Chart.
Has Engine Always Done This?
Check:
Was Engine Used For A Long Time?
Check:
Is This A New Condition? Check:
Hard Starting - Hot Engine
Has Engine Always Done This?
Check:
Ask these questions first:
1. Fuel tank antisiphon valve (if equipped)
2. Fuel lines for obstructions
3. For debris inside fuel tank
4. See Electrical/Ignition/Fuel System Service Manual
1. For clean external fuel filters
2. Water in fuel due to condensation
3. Fuel quality deterioration
4. See Electrical/Ignition/Fuel System Service Manual
1. Fuel tank antisiphon valve (if equipped)
2. Fuel system for leaks, dirt, or obstructions
3. Engine and ignition system
4. See Electrical/Ignition/Fuel System Service Manual
Ask these questions first:
1. Fuel tank antisiphon valve (if equipped)
2. See Electrical/Ignition/Fuel System Service Manual
Is This A New Condition? Check:
1. Brand, type or octane of fuel
2. Spark plugs
3. Water in fuel
4. Condition of battery and cables
5. Starter motor for overheat damage
22 VPA 7746872 English 2006-10
General Information
Did Engine Refuse To Start After
Being Run? Check:
Ignition coil(s)/ignition module
Engine Runs Rough
If At Slow Speed - Check: 1. Fuel tank antisiphon valve (if equipped)
If At High Speed - Check:
1. Ignition system primary circuit
2. Engine timing
3. Fuel tank antisiphon valve (if equipped)
4. See Electrical/Ignition/Fuel System Service Manual
2. Idle speed
3. Engine timing and spark plugs
4. Fuel pressure
5. Water or contaminants in fuel
6. Manifold vacuum leak
7. See Electrical/Ignition/Fuel System Service Manual
1. Air leak on suction side of fuel system
2. Too low octane fuel
3. Ignition system secondary circuit
4. Engine timing
Engine Noises and Vibrations
Valves - Hydraulic Lifters 1. Rapping only when starting (oil too heavy for prevailing weather,
Ignition System (Ping or Knock)
5. Fuel filter
6. Fuel pump pressure
7. Engine compression
8. Water or contaminants in fuel, water in cylinders
9. See Electrical/Ignition/ Fuel System Service Manual
varnish on lifter, oil needs to be changed)
2. Intermittent rapping (leakage at lifter check ball)
3. Idle noise (excessive leak down rate, faulty check ball seat)
4. Generally noisy (excessive oil in crankcase, stuck lifter plunger)
5. Loud noise at operating temperature (scored lifter plunger, fast
leak down rate, oil viscosity too light for prevailing weather or operating temperatures)
6. See appropriate Engine section
1. Incorrect spark plugs
2. Incorrect spark plug wire routing
3. Use higher octane fuel
4. See Electrical/Ignition/Fuel Service Manual
Cooling System
1. Supply pump
2. Loose belts, pulleys
VPA 7746872 English 2006-10 23
General Information
3. See Cooling System section
Crankshaft Balancer or Flywheel
Engine Overheats
Mountings
Alternator
Sterndrive
1. Loose, broken or worn engine mounts
2. Loose lag screws holding mounts to stringer
3. Check engine alignment see Removing and Installing Engine sec-
tion
1. Loose bolt(s)
1. Loose pulley, worn bearings
2. Loose mounting bolts
1. Failed U-joints or gimbal bearing
2. Damaged internal drive components
3. Worn, bent or broken propeller hub or blades
4. Loose, worn or damaged engine coupler
1. Actual engine temperature by verifying with an accurate thermom-
eter
2. Gauge operation and wiring circuit
3. Sending unit operation and wiring circuit
4. Supply pump, circulating pump and belt(s)
5. Water intake screens for blockage
6. Thermostat
7. Water supply hoses
8. Engine timing
9. Water leaks on pressure side of supply pump
10. Air leaks on suction side of supply pump
11. Engine compression
Engine Dies Out
Loss Of, Or Out Of, Fuel - Check: 1. Fuel gauge operation and wiring
2. Fuel level in tank
3. Water or debris in fuel
4. Fuel pickup tube and screen blockage
5. Fuel tank vent blockage
6. Plugged fuel filter
7. Air leak on suction side of fuel system
8. Fuel leak on pressure side of fuel system
9. Inoperative, restricted or incorrectly sized anti-siphon valve
10. Boat fuel lines too small in diameter
11. Fuel pump pressure and suction
24 VPA 7746872 English 2006-10
General Information
12. See Electrical/Ignition/Fuel System Service Manual
Loss Of Ignition - Check:
Engine Stops Or Dies Out Due To
Seizure - Check:
1. Primary and secondary ignition circuits
2. Ignition switch
3. Circuit breakers
4. Wiring between engine and dash
5. Main engine harness wiring
6. See Electrical/Ignition/Fuel Service Manual
1. Sterndrive for internal damage
2. Oil pressure gauge
3. Crankcase oil level
4. Water in engine or sterndrive oil
5. Temperature gauge and cooling system operation
6. Internal engine components as required
Engine Won’t Reach Operating RPM
1. Fuel type or octane
2. Propeller pitch or diameter, damaged blades, slipping hub
3. Crankcase oil level
4. Marine growth on hull and drive
5. Wrong Sterndrive gear ratio
6. Operating at high altitude
7. Restricted air intake
8. Restricted exhaust outlets in engine, transom bracket or drive
9. Poor cylinder compression
10. Fuel pump pressure and vacuum
11. Boat overloaded, or load improperly placed
12. Engine overheating
13. Engine timing and ignition system operation
14. Remote control cables and linkage for proper attachment and
travel
Defective Engine Lubricating System
Engine Components - Check: 1. Clogged or incorrect oil filter
2. Worn oil pump gears, cover or shaft
3. Worn or collapsed oil pump relief valve spring, or foreign material
caught on valve seat
4. Oil pump relief valve plunger loose in cover
5. Damaged filter bypass grommet
6. Clogged oil pickup screen, broken tube or housing
7. Plugged crankshaft or blocked oil galleys
VPA 7746872 English 2006-10 25
General Information
8. Dirty or defective hydraulic lifters, clogged push rod passages
9. Poor quality, incorrect viscosity or oil level
10. Incorrect hose routing on remote filter systems
11. Water in crankcase oil from condensation, defective head gasket,
oil cooler, or cracked manifold/block water passages
Oil Pressure Warning System -
Check:
1. Oil gauge/warning horn operation and wiring
2. Engine temperature
3. Oil pressure gauge and warning horn sender operation and wiring
Low Battery Voltage After Short Storage
Engine/Boat Components - Check: 1. All electrical accessories including ignition circuit off
2. Disconnect main battery negative cable from battery
3. Connect ammeter or voltmeter in series between negative battery
cable and negative battery post
• Meter reading of “0” indicates no draw, test battery and charging system
• Meter movement no matter how slight indicates draw from battery
4. Disconnect main engine harness 10-Pin Connector
• Meter drops back to “0”, problem caused by boat system, continue to isolate each boat electrical accessory until problem is
found
• Meter does not drop back to “0”, problem caused by engine
electrical system, continue to isolate each engine electrical
accessory until problem is found
5. Repair or replace components as necessary
26 VPA 7746872 English 2006-10
Loading...