Volvo 4.3GXi-F, 4.3OSi-F, 5.0GXi-F, 5.0OSi-F, 5.7Gi-F User Manual

...
4.8 (8)

Workshop Manual

 

C

EGC Diagnostics

 

2(0)

 

 

 

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)

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

General Information

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

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 manual, 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 disassembly 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 & Volvo Penta reserves the right to make changes at anytime, without Specifications 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-

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General Information

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.

Engine Compression Testing During all work done around the engine, while the engine is running or 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

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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 at the PCV valve port), following the gauge manufacturer’s instructions. Start and warm up the engine.

2.Observe the vacuum gauge while operating the engine over a range of engine speeds.

Test Results 1. A steady vacuum reading between 14 and 19in. Hg. (47-64 kPa) at idle indicates an engine in good mechanical condition.

2.A vacuum reading below 14 in. Hg. (47 kPa) at idle, indicates an engine that is not developing enough vacuum. Further testing for base mechanical problems is needed.

3.Possible causes of low intake manifold vacuum are late ignition timing, low compression, poor engine sealing, leaks at vacuum lines and connections or bad MAP sensor.

4.If the gauge fluctuates at idle, possible causes are sticking or leaking valves, or an ignition miss.

5.If the gauge fluctuates at idle but smooths out as engine RPM increases, check for bad valves or camshaft.

6.If the gauge fluctuates more with increases engine RPM, check for weak or broken valve springs, bad valves, ignition miss, or a leaking head gasket.

7.If the vacuum gauge fluctuates regularly with each engine cycle, check for a bad valve.

6

VPA 7746872 English 2006-10

Volvo 4.3GXi-F, 4.3OSi-F, 5.0GXi-F, 5.0OSi-F, 5.7Gi-F User Manual

General Information

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

 

15

 

15

 

15

 

15

10

20

10

20

10

20

10

20

10

20

5

25

5

25

5

25

 

25

5

 

0

30

0

30

0

30

0

30

0

30

 

In./Hg.

 

In./Hg.

 

In./Hg.

 

In./Hg.

 

In./Hg.

 

A

 

B

 

C

 

D

 

E

15

 

 

20

10

 

 

5

 

 

0

30

In./Hg.

 

In./Hg.

FG

 

15

 

15

10

20

10

20

5

25

5

25

0

30

0

30

 

In./Hg.

 

In./Hg.

 

15

 

15

 

15

10

20

10

20

10

20

5

25

5

25

5

25

0

30

0

30

0

30

 

In./Hg.

 

In./Hg.

 

In./Hg.

 

H

 

I

 

J

 

15

 

15

 

15

10

20

10

20

10

20

5

25

5

25

5

25

0

30

0

30

0

30

 

In./Hg.

 

In./Hg.

 

In./Hg.

 

K

L

M

N

O

 

 

 

 

 

 

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).

 

 

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)

 

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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 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.

Premium fuels contain injector cleaners and other additives that protect the fuel system and provide optimum performance.

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. Volvo Penta 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.

Gasoline Containing Alcohol

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

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General Information

Crankcase Oil

Draining and Filling the Engine

Crankcase

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.

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

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General Information

oil, use motor oil of the same viscosity.

Table 2: Temperature Viscosity Recommendations

If the lowest Anticipated

The Following SAE Viscosity

Temperature is:

Oils are Recommended

 

 

 

 

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

 

 

Sterndrive

 

 

4.3GXi/OSi

5.0 qts. (4.7 liters)

 

 

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.

Off-Season Storage

There are nine steps that must be completed for Off-Season Storage

Preparation

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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 30day 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 pre-

 

vent 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 accom-

 

plished through fogging. Today’s fuel injection manifolds are designed

 

with a complex air channel design that will not allow the traditional fog-

 

ging 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.

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General Information

 

Run the engine on the storage mixture for approximately 5 min-

 

 

utes 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.

Electric Fuel Pumps and Fuel Cells

Regardless of the ratio of fuel stabilizer to fuel we use, the maximum

 

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 six-

 

month 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 cer-

 

tainly 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 opera-

 

tion to be sure the reservoir is receiving the correct volume of fuel. The

 

same information would apply to engines with the earlier vapor sepa-

 

rator 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, accumu-

 

 

lated 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. Fol-

 

 

low the procedure under Draining and Filling the Engine

 

 

Crankcase.

 

Install a new oil filter and fill crankcase with recommended oil.

Caution!

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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.

Change Sterndrive Lubricant

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.

Drain Cooling System

D

C

A

B

23681

4.3GXi, 4.3OSi

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.

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 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 thermostat 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.

Port 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.

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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 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.

Port 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.

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.

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.

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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 distributor 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 missing 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.

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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 voltmeter, oil pressure and water temperature gauges frequently to be sure all systems are operating properly. Check for fuel, oil, and water leaks.

Engine Break-in

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 threefourths 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 operating 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.

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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 gradu-

 

ally. 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 immedi-

 

ately 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 exces-

 

sive 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.

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Belt Tension

 

 

 

 

1

 

 

 

9

 

 

0

 

8

6

0

 

 

 

 

 

 

 

 

 

3

 

 

 

 

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. Correction 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 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.

13.Make sure engine can achieve maximum rated RPM. See engine specifications.

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

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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 ventilation is provided by a fixed orifice located in the port valve cover and connected by a hose to the intake manifold.

With Engine Idling 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.

With Engine Stopped Remove PCV valve from its mounting and shake it. A metallic clicking 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.

Servicing PCV Valve

Caution!

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

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General Information

malfunction, refer to the individual system troubleshooting charts to isolate the specific cause.

Engine Does not Start

 

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:

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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 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

Engine Will Not Crank

Starter Circuit - Check: • Battery condition: weak, dead, sulfated, bad cells

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

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Fuel System - Check: • Quantity and condition of fuel in boat tank

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

Cylinder Compression - Check • Conduct test following procedure in this section, and compare readings to Compression Limit Chart.

Hard Starting - Cold 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

Was Engine Used For A Long Time? 1. For clean external fuel filters Check: 2. Water in fuel due to condensation

3.Fuel quality deterioration

4.See Electrical/Ignition/Fuel System Service Manual

Is This A New Condition? Check: 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

Hard Starting - Hot Engine

Has Engine Always Done This?

Check:

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

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Did Engine Refuse To Start After

1.

Ignition system primary circuit

Being Run? Check:

 

 

Ignition coil(s)/ignition module

2.

Engine timing

 

3.

Fuel tank antisiphon valve (if equipped)

 

4.

See Electrical/Ignition/Fuel System Service Manual

Engine Runs Rough

If At Slow Speed - Check: 1. Fuel tank antisiphon valve (if equipped)

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

If At High Speed - Check: 1. Air leak on suction side of fuel system

2.Too low octane fuel

3.Ignition system secondary circuit

4.Engine timing

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

Engine Noises and Vibrations

Valves - Hydraulic Lifters Rapping only when starting (oil too heavy for prevailing weather, 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

Ignition System (Ping or Knock) 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

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3.See Cooling System section

Mountings 1. Loose, broken or worn engine mounts

2.Loose lag screws holding mounts to stringer

3.Check engine alignment see Removing and Installing Engine section

Crankshaft Balancer or Flywheel 1. Loose bolt(s)

Alternator 1. Loose pulley, worn bearings

2.Loose mounting bolts

Sterndrive 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

Engine Overheats

1.Actual engine temperature by verifying with an accurate thermometer

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

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12.

See Electrical/Ignition/Fuel System Service Manual

Loss Of Ignition - 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

Engine Stops Or Dies Out Due To

1.

Sterndrive for internal damage

Seizure - Check:

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

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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 - 1. Oil gauge/warning horn operation and wiring

Check: 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

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