Volvo Penta HU series Workshop Manual
Z~ Safety Warning
This Workshop Manual will alert you to certain procedures that
must be done very carefully. If you ignore this information,
you could...
® injure yourself or people around you
®
Injure the boat operator, boat passengers, or
people around the boat
®
Damage the Volvo Penta product or its systems
Understand the following symbols before proceeding:
Z~I Safety Warning
Alerts you to the possibility of danger and
identifies information that will help pre-
vent injuries.
identifies information that will help prevent damage to machinery.
Appears next to information that controls
correct assembly and operation of the
product.
This Workshop Manual is written for qualified, factory trained
service technicians familiar with the use of Volvo Penta special
tools.
This Workshop Manual tells you how to correctly maintain and
service Volvo Penta products and systems. When correctly
serviced, the Volvo Penta product will be reliable and safe to
operate.
When Volvo Penta special tools are called for, use them.
Where mentioned, the tools are required to perform the service
procedure.
If you use service procedures or service tools that are not
recommended in this manual, YOU ALONE must decided if
your actions might injure people or damage the Volvo Penta
product.
Contents
General Information ........................................
3.0 Engine ............... . .....................................
4.3, 5.7 Engines .......................... . ..................
5.0, 5.8 FL Engines ........................................
5.0, 5.8 Fi Engines .........................................
7.4, 8.2 Engines. ......................... ......... ......... .
Steering Systems - SX ....................................
Control Systems - SX .....................................
Cooling Systems ....
.... .................. .......... .........
Engine Removal and Installation - SX ..............
Safety ...............
..... ..................... . ..................
© 1995 Volvo Penta of the Americas, Inc. All Rights Reserved
i
This workshop manual is one of a set of nine that covers Volvo Penta stem
drive models. All nine books can be ordered as a set from Volvo Penta
Parts. Order P/N 7788850-1.
Individual workshop manuals covering these models are also available.
Order the following part numbers from Volvo Penta Parts.
® P/N 7788851-9 SX Dfve Unit and Transom Shield
Includes information on Transom Shield, Upper Gear Unit and Lower Gear
Unit service; Drive Unit removal and installation; Propellers; and Trim/Tilt hy-
draulic operation.
® P/N 7788856-8 E~g/ne Components
Includes information on Engine service and troubleshooting; Engine removal
and installation; Steering systems; Throttle and Shift Comrol systems; and
Cooling systems.
¯ P/N 7788857-6 BectffcN &/gnit~n System
IncJudes service and troubleshooting information on Cranking systems; Charging
systems; Trim/Tilt electrical systems; Ignition systems; and Engine and Instrument widng diagrams.
¯ P/N 7788858-4 Furl System
Includes service and troubleshooting information on all carburetor, MR and
TB! fuel systems and related components.
¯ P/N 7788852-7 MR L~’agno~ Manual (5.0 R, 5.8 F~:Si) - Ford
Includes step by step troubleshooting procedures for all MFI Ford related
components and wiring.
, P/N 7788853-5 TBIDiagimsti
c"
Manual (4.3 G~ 5. 7 Gi) -
Contains troubleshooting procedures for all TBI GM models and related cornponents.
® P/N 77888550 SP and DP Workshop Manual
Includes Upper Gear Unit and Lower Gear Unit overhaul procedures, installa-
tion and removal.
, P/N 7788854-3 MR Diagnostic Manual (7.4 Gi. Z4 G~) -
includes step by step troubleshooting procedures for all MFi GM related components and wiring,
¯ P/N 7788859-0 DPX- Lower Unit Workshop Manual
includes specific information for repair and overhaul of the DPX Lower unit and
Xact
TM
steering systems not covered in the SP and DP Workshop manual°
ii
This Volvo Penta Stern Drive Workshop Manual
Covers The Following Volvo Penta "HU" Models
SX
~,
Engine
Model Nr.
Transom Shield
3.0 GS SX NPS 3868181
38682881SX-LIMITED TRIM
3,0 GS SX 3868182
3868288/SX-LIMITED TRIM
4.3 GL SX 3868184 3868176/SX-C
4.3 GS SX 3868186 3868178/SX-C
5,0 FL SX 3868189
38681761SX-C
6,0 Fi SX
3868193
3868176/SX-C
6=8 FL SX 3868190 3868176/SX-C
5.8 FI SX 3868194 38681761SX-C
5.8 FSi SX 3868195 3868176/SX-C
H.A. = high altitude applications
DuoProp
®
Engine Model Nr. Transom Shield
4.3 Gi DP 3868320 38682991DP-S
4.3 GS DP 3868321
3868299/DPOS
5.0
FL DP
3868322 38682991DP-S
5.0 F| DP 3868323 3868299/DP-S
5.7 Gi DP
3868325
3868299/DP-S
5.8 FL DP 3868324 3868299/DP-S
5.6 Fi DP * 3868326 38682991DP-S
5.8 FSi DP 3868327 3868299/DP-S
7.4 GL DP
3868328 38682991DP-S
7.4 G| DP 3868335 38682991DP-S
t
" = export on!y H.A. = high altitude applications
DPX
~
Engine
Model Number Transom Shield
7.4 GSi DPX-CA 3868198
3868289/DPX-C
/
7.4 GS| DPX-CB3868198 38682891DPX-C
7.4 GSi DPX-CC3868198 3868289/DPX-C
8.2 GL DPX-CA 3868133 3868289/DPX-C
8.2 GL DPX-CB 3868133 3868289/DPX-C
8.2 GL DPX-CC 3868133 38682891DPX-C
Drive Unit
3868159/SX-CTIl.85:l
3868159/SX-CT/l.85:l
38681601SX-C/1.66:1
3868160/SX-Cll .66"1
3868160/SX-C/1.66:1
38681611SX-CI1.60:1
38681621SX-C/1.51:1
38681621SX-CI1.51:1
38682081SX-CI1.43:1
Drive Unit
3868008/D P-C 112.30:1
3868008/D P-C 112.30:1
3868002/DP-Cl!1.95:1
38680021DP-Cl/1.95:1
38680021DP-C 1/1.95:1
38680021DP-C 1/t .95:1
3868002/DP-Cl11.95:1
38680021DP=Cl/1.95:1
3868022/DP-D111.78:1
38680221DP-DlI1.78:l
N.A. = Not Available
Drive Unit
38680201DPX-C/1.59:1
3868021/DPX-C I1 °68:1
3868023/DPX-C/1,78:1
3868020/DPX-C 11.59:1
38660211DPX-C I1.68:1
3868023/DPX-C I1 o76:1
Options
3868176/sx-c
3868t76/SX-C
3868159/SX-C/1.85:llH.A.
3868159/SX-C/1.85:11H.A.
38681591SX-CI1.85:11H.A.
38681601SX-CI1.66:11 HoA.
3868160/SX-CI1.66:11 H.A.
38681601SX.CI1.68:11 H.A.
3868162/SX-C/1.51:l/H.A.
Options
3868008/DP-C 1/2.30:1/H.A.
38680081DP-CII2.30:llH.A.
3868008/DP-C1/2.30:11H.A.
38680081DP-C1/2.30: l lH.A.
3868008/DP-C l12.30: l lH.A.
38680221DP-D1/1.78:1
38680021D P-C 1/1.95: I/H,A.
N.A.
This Volvo Penta Stern Drive Workshop Manual
Covers The Following Volvo Penta "NC" Models
SX"
Engine
3.0 GS SX NPS
3.0 GS SX
4.3 GL SX
4.3 GS SX
5.0 FL SX
5.0 Fi SX
6.7 Gi SX
5.8 FL SX
6.8 FSi SX
Model Nr. Transom Shield Drive Unit
3868181 36684321SX-LIMITED TRIM 38683961SX.CTI1.85:l
3868182
38684321SX-LIMITED TRIM
38683961SX-CTI1.85:l
3868184 38684041SXIDP 3868395/SXll .66
3868186 38684041SXIDP 3868395/SXI1 °66
3868414 3868404/SXIDP 38683951SX/1.66
3868416 38684041SXIDP 3868394/SXl1.60
3868429 38684041SX/DP 3668393/SXI1.51
3868415 38684041SXIDP 3868393/SXI1.51
3868418
38684041SXIDP 38683931SXI1.5t
H.A. = high altitude applications
DuoProp
®’
Engine Model Nr. Transom Shield
4.3 GL DP
3868164
38684041SX/DP
4.3 GS DP 3868186
38684041SXIDP
4.3 Gi DP
3868185 38684041SX/DP
6.0 FL DP 3868414
38684641SXIDP
5.0 Fi DP
3868416 38684041SXIDP
6.7 Gi DP
3868429 3668404/SX/DP
8.8 FL DP 3868415
38684041SXIDP
5,8 FSi DP 3868418
38684041SXIDP
7.4
GL DP
3868196
38684041SXIDP
7.4 Gi DP 3868450
38684041SX/DP
* = for export only H.A. = high altitude applications
Drive Unit
3868163/DPI2.30
38681631DPI2.30
38681631DPI2.30
38681641DPI1.95
3868164/DPll .95
38681641DP/1.95
38681641DPIl.g5
3868164/DP/1.95
3868022/DP-D111,78:1
3868166/DPI1.68
N.A. = Not Available
Options
386839711.97/SXC
386404/TSK
386839711.971SXC
386404/TSK
3868465/SXl1.85
3868465/SXI1.65
N.A.
3868395/SXll .66
N.A.
N.A.
N.A.
Options
N.A.
N.A.
N.Ao
N.A.
N.Ao
N.A.
N.A.
38681651DPII.78
N.Ao
N,A.
Engine Model Nr.
Transom Shield
7.4 GSi DPX-CA 3868198
3868289/DPX
7.4 GSi DPX-CB 3868198
38682891DPX
7.4 GSi DPX-CC 3868198
38682891DPX
8.2 GL DPX-CA 3868133
38682891DPX
8.2 GL DPX-CB 3868133
38682891DPX
8.2 GL DPX-CC 3868133
38682891DPX
Drive Unit
38680201DPX 11.59:1
38680211DPX 11,68:1
38680231DPX It ,78:1
3868020/DPX 11.59:1
38680211DPX 11.68:1
38680231DPX 11.78:1
iv
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