Volvo Penta 3.0GL-C, 4.3GXI-B, 4.3GL-A, 4.3GXI-A, 4.3GXI-BF Operator's Manual

OPERATORS MANUAL

Engine Models

3.0GL-B/C

4.3GL-A, 4.3GXi-A/B(F)

5.0GL-A/B, 5.0GXi-A/B(F), 5.7GL-A/B, 5.7Gi-A/B(F), 5.7GXi-B/C(F)

8.1Gi-B(F), 8.1GXi-A(F), DPX375-A, DPX420-A

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Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Factors that affect engine performance . . . . . . . . 6

How load conditions affect the

speed of a planing hull . . . . . . . . . . . . . . . . . 6

“Wagon-back” effect . . . . . . . . . . . . . . . . . . . 6

Your new boat . . . . . . . . . . . . . . . . . . . . . . . 6

Boater’s responsibilities . . . . . . . . . . . . . . . . 7

Planning your trip . . . . . . . . . . . . . . . . . . . . . 7

Safety equipment . . . . . . . . . . . . . . . . . . . . . 7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Basic safety rules of boating . . . . . . . . . . . . . 7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

High performance boat operation . . . . . . . . . . . . 8

General Information . . . . . . . . . . . . . . . . . . . . . . . 11

Doing your own maintenance and repairs . . . . . 11

Parts and accessories . . . . . . . . . . . . . . . . . . . . 11

Volvo Penta dealer network . . . . . . . . . . . . . . . 12

Volvo Penta on the Internet . . . . . . . . . . . . . . . . 12

Warranty information . . . . . . . . . . . . . . . . . . . . . 13

2 PLUS 4™ Extended Protection . . . . . . . . . . . 13

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Circuit breakers and fuses . . . . . . . . . . . . . . . . 15

3.0 GS-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.0 GS-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3GL-A, 5.0GL-A/B, 5.7GL-A/B . . . . . . . . . . . . 20

4.3GXi-A, 5.0GXi-A, 5.7Gi-A, 5.7GXi-B . . . . . . 22

4.3GXi-B, 5.0GXi-B, 5.7Gi-B, 5.7GXi-C . . . . . . 24

4.3GXi-BF, 5.0GXi-BF, 5.7Gi-BF, 5.7GXi-CF . . 26

8.1Gi-B, 8.1GXi-A . . . . . . . . . . . . . . . . . . . . . . . 28

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DPX 375, DPX420 . . . . . . . . . . . . . . . . . . . . . . 30

Anodes (“sacrificial”) . . . . . . . . . . . . . . . . . . . . . 32

Audible alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Engine systems . . . . . . . . . . . . . . . . . . . . . . . . . 32

Emergency stop switch . . . . . . . . . . . . . . . . 33

Engine protection mode (EFI systems) . . . . 34

Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Engine instruments . . . . . . . . . . . . . . . . . . . 34

Trim instruments . . . . . . . . . . . . . . . . . . . . . 35

Trim/tilt motor protection . . . . . . . . . . . . . . . 37

Impact protection . . . . . . . . . . . . . . . . . . . . 37

Power trim/tilt . . . . . . . . . . . . . . . . . . . . . . . 38

Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Drive unit, rotation, and propellers . . . . . . . . . . . 40

Propeller rotation . . . . . . . . . . . . . . . . . . . . . . . . 40

Remote controls . . . . . . . . . . . . . . . . . . . . . . . . 42

Trim controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operating trim controls . . . . . . . . . . . . . . . . . . . 43

Engine break-in period . . . . . . . . . . . . . . . . . . . 45

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operating after break-in period . . . . . . . . . . . . . 46

Before starting . . . . . . . . . . . . . . . . . . . . . . 47

Starting the engine, cold start . . . . . . . . . . . 47

Starting the engine (warm start) . . . . . . . . . 48

Stopping the engine . . . . . . . . . . . . . . . . . . 49

Operating remote controls . . . . . . . . . . . . . 49

Side mount control . . . . . . . . . . . . . . . . . . . 49

Top mount control . . . . . . . . . . . . . . . . . . . . 49

Steering system operation . . . . . . . . . . . . . . . . 50

Twin unit steering . . . . . . . . . . . . . . . . . . . . 50

Power trim and tilt operation . . . . . . . . . . . . 51

Power trim operation . . . . . . . . . . . . . . . . . . . . . 51

Determining the proper trim . . . . . . . . . . . . 51

Operating in “bow-up” position . . . . . . . . . . 52

Operating in “bow-down” position . . . . . . . . 52

Power tilt operation . . . . . . . . . . . . . . . . . . . . . . 53

Power trim/tilt switch operation . . . . . . . . . . 53

Power trim/tilt switch and gauge location . . 54

Shifting and controlling speed . . . . . . . . . . . . . . 54

Checking instruments . . . . . . . . . . . . . . . . . . . . 55

Special boating circumstances . . . . . . . . . . . . . 56

Shallow water operation . . . . . . . . . . . . . . . 56

High altitude operation . . . . . . . . . . . . . . . . 56

Operating procedure for

freezing temperatures . . . . . . . . . . . . . . . . . 56

Salt water operation . . . . . . . . . . . . . . . . . . 56

Twin unit operation . . . . . . . . . . . . . . . . . . . 56

Trailering your boat . . . . . . . . . . . . . . . . . . . . . . 57

Propeller selection . . . . . . . . . . . . . . . . . . . . . . . 57

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . 58

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Preparing for boating after storage (launching) . 60 Off-season storage preparations (“winterization”) 60

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . 60

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Gasoline recommendations . . . . . . . . . . . . 61

Gasoline containing alcohol . . . . . . . . . . . . 61

Detonation (spark knock) . . . . . . . . . . . . . . 61

Carburetor GL . . . . . . . . . . . . . . . . . . . . . . 62

Electronic fuel injection Gi, GXi . . . . . . . . . . 62

Flame arrestor . . . . . . . . . . . . . . . . . . . . . . 62

Electric fuel pumps . . . . . . . . . . . . . . . . . . . 62

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Engine fuel filter replacement . . . . . . . . . . . 63

Carburetor fuel filter replacement . . . . . . . . 63

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Batteries and connections . . . . . . . . . . . . . . . . . 64

Multiple batteries and selector switch . . . . . . . . . 66

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Contents

Distributor cap and rotor . . . . . . . . . . . . . . . . . . . 67

Circuit breakers and fuses . . . . . . . . . . . . . . . . . 67

Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Checking and changing spark plugs . . . . . . . . . . 68

Belt adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Draining the cooling system . . . . . . . . . . . . . . . . 71

Engine — Closed Cooling (F) engines . . . . . . . . 72

Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Power trim/tilt fluid level . . . . . . . . . . . . . . . . . . . 74

Steering reservoir fluid level . . . . . . . . . . . . . . . . 74

Primary shaft spline and bearing lubrication . . . . 74

Tie rod (twin installations only) . . . . . . . . . . . . . . 74

Checking engine oil level . . . . . . . . . . . . . . . . . . 75

Changing engine oil . . . . . . . . . . . . . . . . . . . . . . 75

Changing the oil filter . . . . . . . . . . . . . . . . . . . . . 75

Engine and Drive Service . . . . . . . . . . . . . . . . . . . 76

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 77

Engine/crankcase oil . . . . . . . . . . . . . . . . 77

Drive components . . . . . . . . . . . . . . . . . . 78

Drive unit lubrication SX . . . . . . . . . . . . . . 78

Anodes (“sacrificial” anodes) . . . . . . . . . . . . . . . 84

Active corrosion protection system . . . . . . . . . . . 85

Propeller care . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Propeller replacement — SX . . . . . . . . . . . . . . . 87

Propeller replacement — DP-S . . . . . . . . . . . . . 88

Propeller replacement — DPX . . . . . . . . . . . . . . 89

Boat bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Engine alignment . . . . . . . . . . . . . . . . . . . . . . . . 90

Replacement parts . . . . . . . . . . . . . . . . . . . . . . . 90

Bottom painting . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Engine submersion . . . . . . . . . . . . . . . . . . . . . . . 90

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.0GS-B, 3.0GS-C . . . . . . . . . . . . . . . . . . . . . . . 92

4.3GL-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.3GXi-A, 4.3GXi-B(F) . . . . . . . . . . . . . . . . . . . . 94

5.0GL-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

5.0GL-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.0GXi-A, 5.0GXi-B(F) . . . . . . . . . . . . . . . . . . . . 97

5.7GL-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

5.7GL-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

5.7Gi-A, 5.7Gi-B(F), 5.7GXi-B, 5.7GXi-C(F) . . . 100

8.1Gi-B(F), 8.1GXi-A(F) . . . . . . . . . . . . . . . . . . 101

DPX375, 420 . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Problem Resolution . . . . . . . . . . . . . . . . . . . . . . . 103

Appendix A: Certified Engines . . . . . . . . . . . . . . 104

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Safety

This owner’s manual contains information you need to operate your boat engine and drive safely. Check that you have the correct manual for your engine and drive.

This manual also contains a considerable amount of information concerning the engine and drive: model identification, preventive maintenance recommendations, fuel and oil recommendations, and other important points. Please keep this book with your boat at all times.

NOTE! It is important that this manual stays with the

boat when it is sold. Important safety information must be passed to the new owner. The service information provided in the manual gives the owner important information about maintaining the engine and drive.

If you do not understand or are uncertain about any operation or information in this owner’s manual, please contact your Volvo Penta dealer. He will be able to help you with an explanation or will demonstrate the operation.

NOTE! Federal law requires manufacturers to notify

owners in the event that a safety related defect is discovered on any of their products. If you are not the original owner of this engine and drive, please notify us at our address listed in this manual, or through an authorized Volvo Penta dealer about the change in ownership. This is the only way we will be able to contact you if necessary.

This manual will alert you to certain things you should do very carefully. If you don’t, you could

— hurt yourself or bystanders

— hurt the boat operator or bystanders

— damage the machinery.

Carefully observe the safety alert symbols shown for dangers, warnings, and cautions. They warn you of possible dangers or important information contained in this manual.

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HOWEVER: WARNINGS ALONE DO NOT ELIMINATE HAZARDS, NOR ARE THEY A SUBSTITUTE FOR SAFE BOAT HANDLING AND PROPER ACCIDENT PREVENTION MEASURES!

DANGER!

FAILURE TO COMPLY WITH A DANGER SYMBOL WILL RESULT IN SERIOUS INJURY OR DEATH TO BOAT OPERATOR, BOAT OCCUPANTS, AND/OR OTHERS.

WARNING!

FAILURE TO COMPLY WITH A WARNING MAY RESULT IN INJURY OR DEATH TO BOAT OPERATOR, BOAT OCCUPANTS AND/OR OTHERS.

CAUTION!

FAILURE TO COMPLY WITH A CAUTION MAY RESULT IN FAILURE OR DAMAGE TO THE EQUIPMENT.

Below is a summary of the risks and safety precautions you should always observe or carry out when operating or servicing the engine:

1. Check that the warning or information decals on the engine are always clearly visible. Replace decals that have been damaged or painted over.

2. Always turn the engine off before starting service procedures. Avoid hot surfaces and liquids in supply lines and hoses when the engine has just been turned off and is still hot.

3. To prevent a possible explosion, operate the blower as recommended by the boat manufacturer before starting the engine. If the engine compartment is not equipped with a blower, open the engine cover or hatch before starting to disperse any gasoline fumes that may be present. Leave the hatch open until after the engine is running.

4. Reinstall all protective parts removed during service operations before starting the engine. Make a point of familiarizing yourself with other risk factors, such as rotating parts and hot surfaces (exhaust manifold, starter, etc.).

5. Approaching a running engine is dangerous. Loose clothing or long hair can get caught in rotating parts and cause

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3

Safety

serious personal injury.

6. If so equipped, turn off the power supply to the engine at the main switch and lock it in the ing work.

7. Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out as system pressure is lost.

8. If opening the filler cap or drain cock/venting cock, or removing a plug or engine coolant line from a hot engine, open the filler cap slowly and release coolant system pressure gradually; otherwise, steam or hot coolant can spray out.

9. Stop the engine and close or block the sea water intake before carrying out operations on the engine cooling system.

10. Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, make sure your work area is well ventilated.

11. Anticorrosion and antifreeze agents can be hazardous to health and to the environment. Whenever you use these agents, follow the manufacturer’s instructions on the product packaging.

12. Certain engine oils are flammable. Some of them are also dangerous if inhaled. Whenever you use these agents, follow the manufacturer’s instructions on the product packaging. Ensure that ventilation in the work place is good. Use a protective mask when spraying.

13. Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before beginning to work on it. Never start or operate the engine with the oil filler cap removed; otherwise, hot oil could spew out.

14. Never allow an open flame or electric sparks near the battery or batteries. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which

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when mixed with air can form an explosive gas. This gas is easily ignited and highly volatile. Incorrect connection of the battery can cause a spark, which would be sufficient to cause an explosion. Do not disturb battery connections when starting the engine (spark risk) and do not lean over batteries.

15. Always ensure that the positive and negative battery leads are correctly installed on the corresponding terminal posts. Incorrect installation can result in serious damage to electrical equipment.

16. Always use protective goggles when charging and handling batteries. Battery electrolyte contains sulfuric acid, which is highly corrosive. If battery electrolyte comes into contact with unprotected skin, wash it off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, immediately flush with copious amounts of water and

OFF

position before start-

obtain medical assistance.

17. To ensure safe handling and to avoid damaging engine components on top of the engine, use a lifting beam to raise the engine. All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine. Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine and any extra equipment installed.

18. If extra equipment is installed on the engine, which alters its center of gravity, a special lifting device is required to achieve the correct balance for safe handling.

19. Never work on an engine that is suspended on a hoist.

20. Components in the electrical, ignition, and fuel systems on Volvo Penta products are designed and constructed to minimize the risk of fire and explosion. Using non-original

Volvo Penta parts that do not meet the above standards can result in fire or explosion on board. Damage

caused by using non-original Volvo Penta replacement parts will not be covered under any warranty provided by Volvo Penta.

21. Fuel filter replacement should be carried out on a cold engine to avoid the risk of fire caused by fuel spilling onto the exhaust manifold. Always cover the generator if it is located under the fuel filter. The generator can be damaged by spilled fuel.

22. Always use protective gloves when tracing leaks. Liquids ejected under pressure can penetrate body tissue and cause serious injury.

23. Always use fuel recommended by Volvo Penta. The use of lower quality fuels can damage the engine. Poor fuel quality can also lead to higher maintenance costs.

24. Never use a high-pressure washer when washing the engine.

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7741591 / 2003-12

Introduction

Congratulations on choosing a new boat equipped with a Volvo Penta marine engine. Volvo Penta has been building marine engines since 1907. Quality, operating reliability, and innovation have made Volvo Penta a world leader in the marine engine industry. From engineering design and manufacturing to support activities in Parts, Service, and Sales, high standards have been set to ensure your pride and satisfaction as the owner of a Volvo Penta product.

As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice, service requirements and replacement parts. Please contact your nearest authorized Volvo Penta dealer for assistance.

We wish you many pleasant voyages.

Our core values: Quality, Safety, Environmental Care

The values and qualities that Volvo Penta expresses are what make the company unique. From the very beginning, safety and quality have stood at the heart of the development of all of our products, processes, and services. It is on these values and qualities that the Volvo Penta corporate identity, brand position and legal status have been founded. Today’s core values of quality, safety, and care for the environment remain central to Volvo Penta. They express what we believe in as a company and will ultimately help us to survive.

Quality

but now encompasses all aspects of our products and services. In today’s competitive environment, Volvo Penta’s quality commitment extends beyond industrial craftsmanship and engineering ingenuity to embrace care for the customer throughout the life of the product.

Safety

torically embedded in the quality of all Volvo products, it also encompasses personal, family, business, and environmental values.

Environmental care

tion, distribution, service, and recycling, is an integral part of

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the Volvo quality commitment towards customers, employees, and the community. By embracing the environment as a core value, Volvo demonstrates its understanding of the environmental impact its products have upon nature and the shared urban and rural surroundings.

Volvo Penta continually commits a considerable part of its development resources toward minimizing the environmental im-

is a value that traditionally referred to product quality

will always be our most distinguishing core value. His-

in all operations, from design to produc-

pact of its products. Examples of areas where we are always looking for improvements are exhaust emissions, noise levels, and fuel consumption.

Regardless of whether your Volvo Penta engine is installed in a boat used for pleasure or commercial operation, incorrect operation or improper maintenance of the engine will result in disturbance or damage to the environment.

In this owner’s manual there are a number of service procedures, which, if not followed, will lead to an increase in the engine’s impact on the environment, and on running costs and a reduction in service life. Always observe recommended service intervals and make a habit of checking that the engine is operating normally every time you use it. Contact an authorized Volvo Penta dealer if you cannot correct the fault yourself.

Remember that most chemicals used on boats are harmful to the environment if used incorrectly. Volvo Penta recommends the use of biodegradable degreasing agents for all cleaning. Always dispose of engine and transmission oil waste, old paint, degreasing agents and cleaning residue etc. at proper disposal areas so that they do not harm the environment.

Adapt speed and distance during your boat trips so that swell and noise generated by the boat do not disturb or harm wildlife, moored boats, docks, etc. Wherever you land or cruise, please show consideration and always leave the areas you visit as you would like to find them yourself.

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5

Introduction

Factors that affect engine performance

Power ratings

A great number of environmental factors, such as barometric pressure, ambient temperature, humidity, the quality of fuel, and exhaust back pressure can affect engine performance. When it comes to quoting and comparing ratings, it is important that there is a unified set of standards for measurement.

In September 1989, all major marine engine manufacturers agreed to quote engine power output according to a common set of conditions. These conditions are referred to as

All Volvo Penta engines meet the ISO 8665 standard.

8665.

This ISO standard outlines the following fixed values or common conditions for determining the rating of the engine.

Condition Value

Sea water temperature 77° F (25° C) Fuel temperature 104° (40° C) Air temperature 77° F (25° C)

Condition

Exhaust back pressure 1.45 PSI (10 kPa) Barometric pressure 14.504 PSI (100 kPa) Relative humidity 30%

A gasoline engine operates with very little surplus air. When conditions deviate from the standard values, the result can be a loss of power at full load. It can also cause a rise in exhaust emissions due to incomplete fuel combustion.

Marine engines can be rated according to one of several power standards, but power output itself is quoted in kilowatts (KW) or horsepower (HP), for a given engine speed, usually at maximum revolutions per minute (RPM).

Value

How load conditions affect the speed of a planing hull

The overall weight of the boat is another important factor in

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performance. Any increase in boat weight will slow down the boat speed, particularly on boats with planing and semiplaning hulls.

For example, a new boat tested with fuel and water tanks only half filled, and without any load, can easily drop 2 to 3 knots in speed when tested fully fuelled and loaded with all normal equipment and supplies for safe and comfortable cruising. This is because the propeller installed originally is frequently one that is designed to give maximum speed when the boat is new. For this reason it is often advisable to reduce the propeller pitch by as much as an inch or more in order to counter the effects of the increase in overall weight encountered in normal cruising, particularly in hotter climates. Although this will reduce top speed somewhat, overall ride conditions will improve and you should achieve greatly enhanced acceleration.

In considering the influence of weight, it is worth remembering that fiberglass boats absorb a significant amount of water into their hulls while left afloat for any length of time and so become

progressively heavier. Another negative influence on boat performance is marine growth beneath the waterline - a problem that is often overlooked.

“Wagon-back” effect

As long as we continue to use combustion technology for engines, there will be exhaust emissions. Despite the substantial reductions achieved in modern engines, as fuel burns exhaust emissions and fumes will always be given off.

ISO

But there is also another effect. Any shear-bodied object moving forward will create a phenomenon we call “wagon-back effect.” Due to a difference in air pressure, the airflow behind such an object will have a tendency to draw dirt and exhaust emissions back into the object. (You’ll frequently see evidence of this in the excess of road grime that is drawn back onto the rear windows of cars.) A boat with a sheer, broad transom and high superstructure creates its own wagon-back effect. This recirculating air has a tendency to draw exhaust fumes and water spray up toward the afterdeck. Often people will make the mistake of opening a ventilator or port hole in order to remove the fumes, but it has the opposite effect — more fumes are drawn in, and conditions merely become worse. In high concentrations these fumes may be hazardous. If you suspect that your boat exhibits this “wagon-back” effect. Please contact your Volvo Penta dealer.

Your new boat

Every new boat has it’s own special characteristics. Even experienced boat owners should note carefully how a boat behaves at different speeds, weather conditions, and loads. Your boat owner’s manual contains information to help you operate it with safety and pleasure. It contains details of the boat, equipment supplied or fitted, systems, and information on operation and maintenance. Please read it carefully, and familiarize yourself with your boat before using it for the first time.

We strongly recommend that you install an emergency stop switch, regardless of the type of boat. If your boat does not

6

7741591 / 2003-12

Introduction

Boater’s responsibilities

The operation, maintenance, and care of the Volvo Penta engine and power package as outlined in the owner’s manual are the owner’s responsibility. (See the The owner must keep records of all maintenance services performed. This record of proper maintenance may be required to determine warranty coverage on certain repairs and should be transferred to each subsequent owner. If you are not sure of the proper maintenance procedures, contact the Volvo Penta Consumer Affairs Department at the address found elsewhere in this document.

The operator is responsible for the correct operation of the boat and for the safety of all passengers. Make sure that all operators read this manual before operating the boat. Show your passengers the location of emergency equipment and explain how to use it. Be sure one of your passengers knows how to handle your boat in case of emergency.

Requirements for personal flotation devices (life vests, life preservers) and other safety equipment vary, depending on the type of boat and local regulations. Always comply with the regulations that apply to your boat.

Maintenance Schedule.

Planning your trip

Everyone wants to have a problem-free and pleasant time when they take their boat out. To help you do this we have provided a pre-journey checklist below. Take extra time to check the engine and its equipment and the general maintenance of the boat.

• Get up to date charts for the planned route

• Calculate distance and fuel consumption

• Note places where you can refuel on your planned course

• Tell friends or relatives about your route (that is, file a “float plan”).

Safety equipment

Basic safety rules of boating

• Shut off the engine when people who are in the water come near the boat.

)

• Propellers are inherently dangerous, and as such are potential safety hazards. Make sure that the propeller is not operating when people who are in the water come near the boat.

• Avoid standing up or shifting weight suddenly in small, lightweight boats.

• Keep your passengers seated in seats. The boat’s bow, gunwale, transom, and seat backs are not intended for use as seats.

• Insist on the use of personal flotation devices by all passengers at all times.

• Know the “rules of the road” and obey them. If you are not familiar with the “rules of the road,” take the U.S. Coast Guard’s boater safety course. You may find information about boating safety at WWW.USCGBOATING.ORG and

WWW.CGAUX.ORG/CGAUXWEB/PUBLIC/ PUBFRAME.HTM.

• Prevent explosion and fire by maintaining your fuel delivery system in top condition. Fuel vapor is volatile; handle fuel with care.

• Keep your boat and equipment neat and in top operating condition. Carry a selection of spare parts for the engine. (Volvo Penta’s on-board kit contains a selection of essential items that a boat owner should carry at all times. See your Volvo Penta dealer.)

• NEVER OPERATE THE BOAT IF YOU ARE UNDER THE

INFLUENCE OF DRUGS OR ALCOHOL.

• If boating waters are unfamiliar, obtain appropriate charts

• Rescue and emergency items such personal flotation de-

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vices and signal rockets. Make sure all passengers know where these items are.

• Replacement parts

• Proper tools

7741591 / 2003-12

7

Introduction

High performance boat operation

High performance is not only defined by engine size, but by a combination of engine power (horsepower), hull design, and the size of the boat. Your new engine(s) produce a high power output. Depending on the boat type, the top speed may be much higher than what you are accustomed to.

High speed operation requires an experienced operator who has mastered handling of high performance boats. It is advisable that you learn the boat’s behavior before you take passengers on board. Inform your passengers about your boat’s characteristics and the maneuvers you intend to do. Use the boat’s performance with due consideration and care!

When operating at high speeds, remember that other boaters may not realize the speed at which you are traveling, especially when you close in on another boat from astern or from ahead. Always keep a good distance to allow for the unexpected! Always be prepared for what other boaters may do unexpectedly. High speed driving requires the driver to give a high degree of attention to boat operation and surrounding conditions.

A boat traveling at a speed of approximately 70 M.P.H. (60 knots) covers about 101 feet (30 meters) in 1 second. The faster you go the quicker things will happen. High speed driving requires a lot of water and a good distance from possible hazards! Always allow for adequate reaction time. Always reduce speed when visibility is reduced for whatever reason.

When driving, make sure that all passengers are safely seated. Emphasize this especially if you have a larger, high performance cabin cruiser where one normally moves about during operation. Reduce speed considerably, or stop completely if someone needs to move about the boat.

The driver should always use the safety kill switch! The kill switch lanyard which is securely connected to the driver, immediately shuts off the engine(s) should the driver be thrown from the driving position. Even if the risk of being thrown overboard is practically nonexistent in your type of boat, the risk of the driver falling and being dazed in rough seas can be even greater.

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Remember, even when the engine(s) is stopped in a high performance boat that is planing, it will travel approximately 325

8

7741591 / 2003-12

Product and Application Information

Please complete this section for future reference.

Delivery date ____________________________________________________________________________

Engine model number _____________________________________________________________________

Engine serial number _____________________________________________________________________

Drive/Transmission model __________________________________________________________________

Drive/Transmission serial number ____________________________________________________________

Transom shield assembly serial number _______________________________________________________

Boat manufacturer _______________________ Boat year ________________________________________

Boat model ____________________________ Boat length ______________________________________

Hull ID number (HIN) ______________________________________________________________________

State/Province registration number ___________________________________________________________

Propeller size____________________________________________________________________________

Selling dealer ____________________________________________________________________________

______________________________________________________________________________________

Servicing dealer__________________________________________________________________________

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______________________________________________________________________________________

It is very important that you obtain all serial numbers directly from serial number plates attached to product assemblies. Check features page for the location of product serial number plates.

© 2001, Volvo Penta of the Americas, Inc. Volvo, Volvo Penta, DP Duoprop, and (Aquamatic) are ® of AB Volvo. DPX and QL are ® of AB Volvo Penta. DuraPlus, 2PLUS4, Speed Rails, and Xact are trademarks of Volvo Penta of the Americas, Inc. SX Cobra and SX Diesel are trademarks of Volvo Penta Marine Products, L.P.

Volvo Penta reserves the right, without prior notice, to revise materials, standard equipment, specifications, models and to discontinue models. Not all models, equipment and accessories are available in all markets or countries. Certain models and/or configurations may

not be available at the time of publication. Representations made regarding these products are subject to actual use, application, and/or operating conditions, as well as proper maintenance. The power rating data contained herein is for engines and conditions as

tested and may vary within manufacturing tolerances. Engines pictured in this brochure may feature custom accessories that are not necessarily standard on production models. Horsepower ratings are in accordance with NMMA procedure.

7741591 / 2003-12

9

General Information

Engine model number

Transom shield model number

Identification numbers

Immediately upon taking delivery of your new boat, have the dealer record the model and serial numbers of the engine and drive in the ed. (These numbers are required for warranty registration, warranty service, and ordering parts.) Include the model and serial number of your boat and any auxiliary equipment. Also, make a copy and keep the copy in a safe place in the event your boat is stolen.

Product and Application Information

space provid-

Owner’s identification card

When you purchased your boat, the dealer was required to complete a warranty and registration form for your Volvo Penta product. The owner’s portion of this form is your Owner’s Identification Card. This card provides proof of ownership and is required to validate warranty, should warranty service be necessary. Warranty coverage may be delayed until the warranty and registration form is on file at Volvo Penta.

Product references, illustrations, and specifications

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. Volvo Penta of the Americas, Inc. reserves the right to make changes at any time, without notice, in specifications and models; to discontinue models; 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.

When reference is made in this manual to a brand name, number, product or specific tool, an equivalent product may be used in place of the product referred to unless specifically stated otherwise. To avoid hazards, equivalent products used must meet all current U.S. Coast Guard Safety Regulations and American Boat and Yacht Council (ABYC) standards.

All illustrations used in this manual may not depict actual models or equipment and are intended as representative views for reference only.

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Drive unit model number

10

7741591 / 2003-12

Toll-free Dealer Locator Service

General Information

Volvo Action Service (VAS)

Volvo Action Service (VAS) is a consumer breakdown service available 24 hours each day, 365 days per year. If your engine breaks down, the VAS coordinator will quickly locate your nearest dealer. If you need a tow, parts, or mechanic, the VAS coordinator will make all arrangements necessary to get you back underway as soon as possible. Membership to Volvo Action Service is provided automatically to all Volvo Penta engine owners. As long as your Volvo Penta engine is under factory warranty, this service is absolutely free for Volvo Penta-related repairs. Towing is not covered by the Volvo Penta warranty. Once your warranty period has expired, there is a charge per managed breakdown, plus any additional costs incurred for towing, parts, or repairs.

If you have a question about Volvo Action Service, or need

additional information, call toll-free 1-877-33-PENTA.

Doing your own maintenance and repairs

If you are away from your home waters, take your Volvo Penta product to the nearest Volvo Penta servicing dealer. To locate a Volvo Penta servicing dealer, check the Yellow Pages under Boat Dealers, or call 1-800-522-1959.

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If you plan to do your own maintenance and repairs on your Volvo Penta products, you should purchase a set of service manuals that pertain to your particular engine and drive. Keep in mind, however, that there are certain tasks that should only be performed by your Volvo Penta dealer. He has the tools, expertise, and most current information needed to properly perform these tasks.

“Dealer-only” maintenance items are listed in the

nance Schedule

.

Mainte-

Parts and accessories

Genuine Volvo Penta parts are the result of many hours of strenuous testing, and fulfill Volvo Penta’s strict quality and safety requirements. Your authorized dealer has a complete line of (or may order) genuine Volvo Penta parts, accessories, coolants, and lubricants. When replacements are required, use only Volvo Penta genuine parts.

Purchase all Volvo Penta replacement parts, accessories, coolants, and lubricants from an authorized Volvo Penta dealer. He has needed parts in stock for routine maintenance, as well as the information needed to order special parts and accessories for you.

Only authorized Volvo Penta dealers may purchase genuine parts and accessories directly from the factory. Volvo Penta

7741591 / 2003-12

11

General Information

Volvo Penta dealer network

Volvo Penta has a comprehensive dealer network that offers both service and spare parts for Volvo Penta engines. These dealers have been carefully selected and trained to provide professional assistance for service and repairs. They also have the special tools and testing equipment required for maintaining a high standard of service. Volvo Penta dealers and vendors must maintain a stock of original spare parts and accessories to cover most requirements of Volvo Penta owners. When ordering a service or spare parts always quote the engine and drive/reverse gear complete type designation and serial number. You will find this information on the engine product plate and on a decal on the valve cover.

Always take your Volvo Penta product to an authorized Volvo Penta servicing dealer for repair. Our dealers have the knowledge, factory-trained technicians, and special tools to take care of any necessary repairs. Ideally, take your product back to your selling dealer — he also knows you and your equipment.

For the name and location of your nearest Volvo Penta dealer, consult the Yellow Pages under

1-800-522-1959.

Boat Dealers,

or call

Volvo Penta on the Internet

The URL address for Volvo Penta of the Americas is http:// www.volvo.com. When you reach the Volvo home page,

choose the bar and then

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Marine and Industrial Power Systems

Marine Leisure

from the drop down menu.

on the menu

12

7741591 / 2003-12

Warranty information

Volvo Penta’s warranty package can be found in the accompanying warranty booklet. Along with the warranty information you will find other checklists and reports for Volvo Penta products.

Some areas may have other warranty conditions, depending on national legislation and regulations. Information about these conditions can be obtained from Volvo Penta importers and dealers in those areas. Contact your local Volvo Penta representative for a copy.

Warranty Registration Form

The Warranty Registration Form should always be filled out and sent in by the dealer. Make sure that this has been done, since delay of warranty claims can occur if no proof of the delivery date can be provided.

2 PLUS 4™ Extended Protection

In addition to our factory warranty, owners may purchase Volvo Penta’s exclusive 2 PLUS 4 Extended Protection plan, which provides additional service benefits for a total of six years of coverage. The 2 PLUS 4 program covers most repairs to Volvo Penta engines, drives, and transmissions, and is fully transferable to second owners.

The extended protection plan provides mechanical coverage, a towing allowance, and optional accessories and trailer coverage. It covers an extensive list of repairs with only a $25.00 deductible per repair visit. See Appendix B of this document for more information about the 2 PLUS 4 Extended Protection

General Information

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7741591 / 2003-12

13

Notes

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

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

14

7741591 / 2003-12

Features

Your Volvo Penta product consists of two components: the engine and the drive. There are certain parts on each component that you, the owner, must take care of to make sure that your Volvo Penta product stays in optimum running condition. The important parts of each component are shown in the photographs on the following “ tems are described below; the maintenance procedures are found in the

Circuit breakers and fuses

Features”

Maintenance

pages. Explanations of these parts and sys-

section.

12

4

3

4.3GL-A, 5.0GL-A, 5.0GL-B, 5.7GL-A, 5.7GL-B

6

2

1

5

4

2

1

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3.0GS-B, 3.0GS-C

1. 40 Amp Harness Fuse

2. Spare Fuse

3. 7.5 Amp Fuel Pump Fuse

4. 50 Amp Circuit Breaker Power Trim Pump

5. 15 Amp Ignition/Fuel Fuse

4.3GXi-A, 5.0GXi-A, 5.7Gi-B/GXi-A

2

4

6

9

10

4.3GXi-B(F), 5.0GXi-B(F), 5.7Gi-B(F),

5.7GXi-C(F), 8.1Gi-B(F), 8.1GXi-A(F), DPX375-B(F), DPX420-B(F)

6. 20 Amp Fuel Pumps

7. 20 Amp Insturment Panel Accessory

8. 15 Amp Engine Control Module (ECM) Fuse

9. 15 Amp Spare Accessory Fuse

10. 20 Amp Spare Accessory Fuse

7

8

5

2

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15

3.0 GS-B

10

1

2

3

4

5

6

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1. Audible Alarm

2. Oil Fill Cap

3. Flame Arrestor

4. Alternator

5. Serpentine Belt

6. Power Steering Fluid Fill

7. Power Steering Pump (Optional)

8. Raw Water Pump

9. Oil Dipstick (Sterndrive)

10. Circuit Breaker and Fuses

11. Oil Dipstick (Engine)

12. Oil Filter

7

8

13. Fuel Pump and Filter

14. Spark Plugs and Wires

15. Anodes

16. Water Intake

17. Exhaust Overheat Sensor

18. Exhaust Riser

19. Engine Flush

20. Water Drain (Exhaust Manifold)

21. Propeller

22. Oil Drain (Sterndrive)

23. Water Drain (Engine)

24. Exhaust Manifold

16

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14

3.0 GS-B

21

9

11

12

13

15

19, 23

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20

18

17

9

21

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17

3.0 GS-C

2

10

1

4

5

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1. Audible Alarm

2. Oil Fill Cap

3. Flame Arrestor

4. Alternator

5. Serpentine Belt

6. Power Steering Fluid Fill

7. Power Steering Pump (Optional)

8. Raw Water Pump

9. Oil Dipstick (Sterndrive)

10. Circuit Breaker and Fuses

11. Oil Dipstick (Engine)

12. Oil Filter

6

7

8

13. Fuel Pump and Filter

14. Spark Plugs and Wires

15. Anodes

16. Water Intake

17. Exhaust Overheat Sensor

18. Exhaust Riser

19. Engine Flush

20. Water Drain (Exhaust Manifold)

21. Propeller

22. Oil Drain (Sterndrive)

23. Water Drain (Engine)

24. Exhaust Manifold

18

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3.0 GS-C

14

11

9

12

21

19, 23

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13

15

3

18

17

9

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20

21

Engine cover removed for clarity

19

4.3GL-A, 5.0GL-A/B, 5.7GL-A/B

23, 30

18

29

1

19

2

3

18

4

6

7

5

8

9

12

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1. Circuit Breaker and Fuses

2. Carburetor

3. Flame Arrestor

4. Alternator

5. Alternator Belt

6. Oil Dipstick (Engine)

7. Oil Siphon Tube

8. Power Steering Fluid Fill

9. Power Steering Pump

10. Power Steering Belt

11. Raw Water Pump

11

12. Fuel Filter

13. Fuel Pump

14. Propeller(s)

15. Oil Dipstick (Drive)

16. Steering Cable

17. Starter

18. Exhaust Overheat Sensors

19. Audible Alarm

20. Exhaust Riser

21. Exhaust Manifold

22. Cooling Water Drain (Manifold)

23. Water Drain (Engine)

24. Spark Plugs

10

25. Anodes

26. Raw Water Intake

27. Oil Drain (Sterndrive)

28. Oil Filter

29. Oil Fill (Engine)

30. Engine Flush

20

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4.3GL-A, 5.0GL-A/B, 5.7GL-A/B

14

15

26

16

22

25

21

17

18

24

20

1

13

23, 30

12

11

4

6

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7

10

9

18

22

15

24

14

28

25

26

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21

4.3GXi-A, 5.0GXi-A, 5.7Gi-A, 5.7GXi-B

19

18

3

18

29

1

5

12

13

4

6

5

7

2

10

8

9

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1. Circuit Breaker and Fuses

2. Belt Tensioner

3. Flame Arrestor

4. Alternator

5. Water Circulation Pump

6. Oil Dipstick (Engine)

7. Oil Siphon Tube

8. Power Steering Fluid Fill

9. Power Steering Pump

10. Serpentine Belt

11. Raw Water Pump

12. Fuel Filter

13. Fuel Pump

14. Propeller(s)

15. Oil Dipstick (Drive)

16. Steering Cable

17. Starter

18. Exhaust Overheat Sensors

19. Audible Alarm

20. Exhaust Riser

11

21. Exhaust Manifold

22. Water Drain (Manifold)

23. Water Drain (Engine)

24. Spark Plugs

25. Anodes

26. Raw Water Intake

27. Oil Drain (Sterndrive)

28. Oil Filter

29. Oil Fill (Engine)

30. Engine Flush

22

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4.3GXi-A, 5.0GXi-A, 5.7Gi-A, 5.7GXi-B

14

15

26

16

22

25

21

18

17

20

23, 30

12

11

24

28

6

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7

10

9

18

22

15

24

14

25

26

7741591 / 2003-12

23

4.3GXi-B, 5.0GXi-B, 5.7Gi-B, 5.7GXi-C

1

18

19

3

18

4

6

5

12

13

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1. Circuit Breaker and Fuses

2. Belt Tensioner

3. Flame Arrestor

4. Alternator

5. Water Circulation Pump

6. Oil Dipstick (Engine)

7. Oil Siphon Tube

8. Power Steering Fluid Fill

9. Power Steering Pumps

10. Serpentine Belt

11. Raw Water Pump

12. Fuel Filter

13. Fuel Pump

14. Propeller(s)

15. Oil Dipstick (Drive)

16. Steering Cable

17. Starter

18. Exhaust Overheat Sensors

19. Audible Alarm

20. Exhaust Riser

5

2

11

21. Exhaust Manifold

22. Water Drain (Manifold)

23. Water Drain (Engine)

24. Spark Plugs

25. Anodes

26. Raw Water Intake

27. Oil Drain (Sterndrive)

28. Oil Filter

29. Oil Fill (Engine)

30. Engine Flush

7

10

8

9

24

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4.3GXi-B, 5.0GXi-B, 5.7Gi-B, 5.7GXi-C

14

15

16

26

25

22

21

18

20

29

12

23, 30

24

17

28

6

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7

10

24

18

22

15

14

25

26

7741591 / 2003-12

25

4.3GXi-BF, 5.0GXi-BF, 5.7Gi-BF, 5.7GXi-CF

1

3

18

29

30

18

4

6

12

13

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21

20

1. Circuit Breaker and Fuses

2. Belt Tensioner

3. Flame Arrestor

4. Alternator

5. Water Circulation Pump

6. Oil Dipstick (Engine)

7. Oil Siphon Tube

8. Power Steering Fluid Fill

9. Power Steering Pump

10. Serpentine Belt

11. Raw Water Pump

12. Fuel Filter

13. Fuel Pumps

14. Engine flush connector

15. Oil Dipstick (Drive)

16. Steering Cable

17. Starter

18. Exhaust Overheat Sensors

19. Audible Alarm

20. Engine flush / Raw water drain valve

7

10

2

8

5

9

11

14, 23

21. Heat Exchanger

22. Water Drain (Manifold)

23. Water Drain (Engine)

24. Spark Plugs

25. Anodes

26. Raw Water Intake

27. Oil Drain (Sterndrive)

28. Oil Filter

29. Oil Fill (Engine)

30. Coolant Fill

26

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4.3GXi-BF, 5.0GXi-BF, 5.7Gi-BF, 5.7GXi-CF

15

16

25

19

18

17

30

24

27

28

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26

18

7741591 / 2003-12

25

26

27

8.1Gi-B, 8.1GXi-A

23

8

22

24

26

9

25

17

20

18

19

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1. Exhaust Riser

2. Exhaust Overheat Sensor

3. Exhaust Manifold

4. Power Steering Cylinder

5. Spark Plugs

6. Oil Dipstick (Sterndrive)

7. Trim Tilt Angle Sensor

8. Fuel Filter

9. Oil Dipstick (Engine)

10. Cooling Water Drain (Exhaust Manifold)

11. Engine Oil Cooler

12. Engine Flush / Engine Drain

21

13. Anodes

14. Raw Water Intake

15. Propellers

16. Oil Drain (Sterndrive)

17. Oil Filter

18. Power Steering Fluid Fill

19. Power Steering Pump

20. Serpentine Belt

21. Raw Water Pump

22. Fuel Pumps

23. Fuses

24. Flame Arrestor

25. Alternator

26. Oil Fill (Engine)

28

7741591 / 2003-12

Volvo Penta 3.0GL-C, 4.3GXI-B, 4.3GL-A, 4.3GXI-A, 4.3GXI-BF Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual