Table of Contents Salt Water Operation ..................................................44 Trailering Your Boat....................................................44 Alternator Belt....................................................... 83 Cooling System .......................................................... 84 Raw Water System............................................... 84 Closed Cooling System (F-Series) ....................... 84 Engine Overheating (Gi & GXi only)..................... 84 Engine Overheating (All other Models)................. 85 Engine Flush ..............................................................
85 Draining the Cooling System...................................... 86 Raw Water Cooled Engines.................................. 86 Draining the Closed Cooling System.......................... 87 8.1 Liter Engines (F-Series).................................. 87 4.3 GL Draining Only ............................................ 87 4.3, 5.0, and 5.7 Liter Engines (F-Series)............. 87 Impeller: Checking & Replacing ................................. 88 Steering System ......................................................... 88 Power Steering Reservoir Fluid Level .................. 89 Power Trim/Tilt Fluid Level.........................................
89 Shaft Spline and Bearing Lubrication ......................... 89 Tie Rod (Twin Installations Only) ............................... 89 Lubrication System................................................. 90 Engine/Crankcase Oil................................................. 90 Checking Engine Oil Level ......................................... 91 Changing Engine Oil .................................................. 91 Changing the Oil Filter................................................ 91 Drive Components.................................................. 92 Drive Unit Lubrication .................................................
92 Checking the Drive Unit Lubricant ........................ 92 Draining the Drive Unit.......................................... 92 Filling the Drive Unit.............................................. 93 Sacrificial Anodes....................................................... 94 Replacing Sacrificial Anodes ................................ 94 Replacing Heat Exchanger Anodes...................... 94 Active Corrosion Protection System........................... 95 Painting the Drive ....................................................... 97 SX and DP-S Drives ............................................. 97 Preparation ...........................................................
97 Paint Application................................................... 97 Propeller Care ........................................................ 98 Propeller Replacement — SX .................................... 98 Removing the SX Propeller .................................. 98 Installing the SX Propeller .................................... 98 Propeller Replacement — DP-S................................. 99 Removing the DP-S Propeller............................... 99 Installing the DP-S Propeller................................. 99 Boat Bottom.......................................................... 100 Bottom Painting ........................................................
100 Engine Alignment ................................................. 100 Engine Submersion .................................................. 100 Replacement Parts............................................... 101 Features 45 Circuit Breakers and Fuses.................................... 45 Legend of Symbols Used in Engine Diagrams ...........45 3.0GLP-C ............................................................... 46 4.3GL-D, 5.0GL-E .................................................. 48 4.3GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F ................. 50 8.1Gi-F, 8.1GXi-E................................................... 52 4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF.........
54 8.1Gi-FF, 8.1GXi-EF .............................................. 55 SX-M Sterndrive..................................................... 56 DP-S Sterndrive ..................................................... 57 Maintenance Parts List 59 Maintenance 61 Engine Break-in Period ..........................................
61 Break-in Procedures...................................................61 First Two Hours ..........................................................62 Next Eight Hours.........................................................62 Final Ten Hours ..........................................................63 First Service Inspection (Dealer 20-Hour Check) .......63 Operating After Break-in Period..................................63 Maintenance Schedule........................................... 64 Static Water Line....................................................
66 Static Water Line Test ................................................66 Preparing for Boating (Launching)..............................67 Off-Season Storage (Winterization)............................67 Maintenance of Boat’s Systems.............................
68 Engine Exhaust System..............................................68 Drive Unit Bellows.......................................................68 Fuel System................................................................69 Gasoline Recommendations.................................69 Gasoline Containing Alcohol.................................70 Detonation (Spark Knock).....................................70 Preventing Gum Formation and Corrosion ...........70 Carburetor (GL).....................................................71 Electronic Fuel Injection (Gi, GXi).........................71 Flame Arrestor ......................................................71 Electric Fuel Pumps ..............................................72 Fuel Filter ..............................................................72 Engine Fuel Filter Replacement............................73 Fuel Filter Replacement (V6/V8 Carb Engines)....74 Fuel Screen Cleaning (3.0 Liter Carb Engines) ....74 Electrical System ........................................................75 Battery Cables.......................................................75 Batteries and Connections....................................75 Battery Replacement.............................................77 Multiple Batteries and Selector Switch..................78 Distributor Cap and Rotor .....................................78 Circuit Breakers and Fuses...................................78 Spark Plugs...........................................................79 Checking and Changing Spark Plugs ...................79 Belt Adjustments.........................................................81 Serpentine Belt Engines........................................81 V-Belt Engines ......................................................82 V-Belt Tension.......................................................82 Power Steering Pump Belt....................................83 7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06 Troubleshooting 103 Troubleshooting - System Isolation......................
103 Engine Troubleshooting Guides........................... 104 Technical Data 113 Metric Conversion Chart 121 Index 123 2 VPA 7743722 English 10-2004