1968-1991 Volvo Penta Inboard and Stern Drive Service & Repair Manual

© 2006 PDF Manual Master ENGINE FINDER The following listings contain all engines covered in this manual. Throughout the year cov- erage of this manual, Volvo Penta used engines manufactured by a number of different sup- pliers, hence we have categorized them by their manufacturer. We have also listed each engine by its size and configuration, and, Volvo's unique designation, if any. All versions of each engine are covered in the pages within, regardless of fuel, ignition or drive system. General Motors 3.SL (229) V6 4.3L (262) V6 5.0L (305) VS 5.0L (307) VS 5.7L (350) VS 7.4L (454) VS S.2L (502) VS 430/4.3L (262) V6 431/4.3L (262) V6 740/7.4L (454) VS AQ175/3.SL (229) V6 AQ200/5.0L VS AQ205/4.3L (262) V6 AQ211/5.0L (305) VS AQ225/5.0L VS AQ231/5.0L (305) VS AQ255/5.7L (350) VS AQ260/5.7L (350) VS AQ271/5.7L (350) VS AQ2S0/5.7L (350) VS AQ290/5.7L (350) VS AQ311/5.7L (350) VS Ford 5.0L (302) VS 5.SL (351) VS 7.5L (460) VS AQ190/5.0L (302) VS AQ240/5.SL (351) VS Volvo 2.0L (121) 4 cyl 2.1 L (130) 4 cyl 2.3L (141) 4 cyl 2.5L (152) 4 cyl 3.0L (1S2) 6 cyl AQ105/2.0L (121) 4 cyl AQ115/2.0L (121) 4 cyl AQ120/2.1L (130) 4 cyl AQ125A12.1 L (130) 4 cyl AQ1258/2.3L (141) 4 cyl AQ130/2.0L (121) 4 cyl AQ131/2.3L (141) 4 cyl AQ140/2.1 L (130) 4 cyl AQ145/2.3L (141) 4 cyl AQ151/2.5L (152) 4 cyl AQ165/3.0L (1S2) 6 cyl AQ170/3.0L (1S2) 6 cyl AQ171/2.5L (152) 4 cyl

© 2006 PDF Manual Master TABLE OF CONTENTS 1 SAFETY INTAKE MANIFOLD V6 OR V8 ENGINE 3-23 INTRODUCTION 1-1 CLEANING, WAXING, POLISHING 1-1 EXHAUST MANIFOLD CONTROLLING CORROSION 1-1 V6 OR V8 ENGINE 3-24 PROPELLERS 1-3 FUEL SYSTEM 1-8 ROCKER ARM SERVICE 3-25 LOADING 1-10 HORSEPOWER 1-11 CYLINDER HEAD FLOTATION 1-11 Removal/Installa tion EMERGENCY EQUIPMENT 1-13 In-line Pushrod Engine 3-25 COMPASS 1-15 Removal/Installation POWER STEERING SYSTEM 1-18 Single OHC Engine 3-28 ANCHORS 1-18 Re mo v al/Installa ti on MISCELLANEOUS EQUIPMENT 1-18 Double OHC (DOHC)Engine 3-29 BOATING ACCIDENT REPORTS 1-19 Removal/Installa tion NAVIGATION 1-19 V6 or V8 Engine 3-33 2 TUNING Head Recondi tioning Disassembling 3-34 INTRODUCTION 2-1 Valve Guides 3-36 TUNING FOR PERFORMANCE 2-1 Valve Springs 3-36 MECHANICAL TASKS 2-1 Valves 3-37 IGNITION 2-5 Hydraulic Lifters 3-38 FUEL SYSTEM 2-9 Valve Seats 3-38 Head Assembling 3-40 3 ENGINE CAMSHAFT SERVICE GENERAL PRINCIPLES 3-1 In-Line Pushrod Engine 3-41 CHAPTER ORGANIZATION 3-3 Single OHC Engine 3-44 TROUBLESHOOTING CHECK 3-4 Double OHC (DOHC) Engine 3-49 ENGINE REMOVAL 3-8 V6 and V8 Engines 3-53 ENGINE INSTALLATION 3-12 VALVE LASH ADJUSTMENT INT AKE/EXHAUST MANIFOLD In-Line Pushrod Engine 3-55 IN-LINE ENGINES 3-16 Single OHC Engine 3-55 INTAKE &: EXHAUST MANIFOLDS Double OHC (DOHC) Engine 3-57 DOUBLE OHC (DOHC) ENGINE 3-17 GMC V6 and V8 Engines 3-57 Exhaust Manifold Removal 3-18 Ford V8 Engines 3-58 Intake Manifold Removal 3-19 Cleaning &: Inspecting 3-20 TIMING BELT SERVICE Intake Installation 3-20 Single OHC Engine 3-59 Exhaust Installation 3-21 Double OHC (DOHC) Engine 3-63

© 2006 PDF Manual Master 3 ENGINE (Continued) SOLEX SIDE-DRAFT 4-25 Description & Operation 4-25 TIMING CHAIN SERVICE Removal & Disassembling 4-25 V6 and V8 Engines 3-65 Cleaning & Inspecting 4-28 PISTON, RING, AND Assembling 4-28 ROD SERVICE 3-68 ROCHESTER 2GC 4-33 CRANKSHAFT AND Disassembling 4-33 MAIN BEARINGS 3-78 Cleaning & Inspecting 4-36 Pushrod and OHC Engines 3-81 Assembling 4-36 V6 and V8 Engines 3-88 Bench Adjustments 4-39 OIL PUMP SERVICE ROCHESTER 4MV 4-41 Pushrod and OHC Engines 3-91 Description 4-41 V 6 and V8 Engines 3-93 Disassembling 4-45 Cleaning & Inspecting 4-47 4 FUEL Bench Adjustments 4-51 INTRODUCTION 4-1 HOLLEY CARBURETORS Single Diaphragm Pump 4-1 2300 - TWO-BARREL Dual-Diaphragm Pump 4-1 4150, 4160 & 4011 - FOUR-BARREL 4-55 TROUBLESHOOTING 4-1 Description 4-55 Rough Engine Idle 4-2 Disassembling -- Model 2300, Excessive Fuel Consumption 4-3 4150 & 4160 4-61 Engine Surge 4-3 Cleaning & Inspecting 4-62 FUEL LINE AND Assembling 4-64 FUEL PUMP TESTS 4-3 Tuning Adjustments 4-67 Fuel Line Test 4-4 Disassembling - Model 4011 4-70 Fuel Pump Tests 4-4 Cleaning & Inspecting 4-77 Pump Pressure Test 4-5 Assembling 4-79 Pump Volume Test 4-5 Tuning Adjustmen ts 4-86 VOLVO FUEL PUMP SERVICE 4-5 CARBURETOR SPECIFICATIONS 4-90 Removal 4-5 Disassembling 4-6 5 IGNmON Cleaning & Inspecting 4-7 Assembling 4-7 DESCRIPTION 5-1 Ballast Resistor 5-2 CARTER FUEL PUMP SERVICE 4-10 Igni tion Timing 5-2 Removal 4-10 IGNITION TROUBLESHOOTING 5-3 Installa tion 4-10 Compression 5-3 System Tests 5-3 FUEL SYSTEM ACCESSORIES 4-11 Voltage Tests 5-6 Fuel Filter Replacement 4-11 SPARK PLUG TROUBLESHOOTING 5-9 Flame Arrester 4-11 Evaluation 5-10 Polar i ty Check 5-12 CARBURETORS DISTRIBUTOR SERVICE 5-12 Introduction 4-11 DISTRIBUTOR REMOVAL 5-14 "Sour" Fuel 4-12 Bosch 5-14 Mallory 5-14 SOLEX DOWNDRAFT 4-12 Autoli te/Prestolite 5-14 Description & Operation 4-12 Removal & Disassembling 4-13 BOSCH DISTRIBUTOR SERVICE 5-14 Cleaning & Inspecting 4-17 Disassembling 5-14 Assembling 4-17 Cleaning and Inspecting 5-16 Adjustments 4-23 Assembling 5-17

© 2006 PDF Manual Master 5 IGNITION (Continued) SERVICING CHARGING SYSTEM WITH SEPARATE REGULATOR MALLORY DISTRIBUTOR SERVICE 5-19 PRESTOLITE 6-16 Removal & Disassembling 5-19 Disassembling 6-16 Cleaning & Inspecting 5-19 Cleaning & Testing 6-16 Assembling 5-21 SERVICING CHARGING SYSTEM AUTOLITE/PRESTOLITE 5-22 WITH INTEGRAL REGULA TOR Disassembling 5-22 PRESTOLITE 6-18 Cleaning & Inspecting 5-23 Disassembling 6-19 Assembling 5-25 Cleaning & Testing 6-19 ADJUSTING POINT GAP SERVICING CHARGING SYSTEM ALL DISTRIBUTORS 5-25 WITH SEPARATE REGULA TOR DISTRIBUTOR INSTALLATION 5-27 SEV MARCHAL AL TERNA TOR 6-21 Adjusting the Dwell 5-28 Removal & Disassembling 6-21 Adjusting Ignition Timing 5-29 Bench Testing 6-21 Assembling & Installation 6-24 RENIX ELECTRONIC IGNITION SYSTEM -- MODEL AQ171 SERIES 5-30 SERVICING CHARGING SYSTEM Description & Operation 5-30 WITH INTEGRAL REGULA TOR Checking Renix System 5-32 DEL COT RON 6-25 Troubleshooting Renix 5-32 Disassembling 6-26 Cleaning & Testing 6-26 ST ANDARD ELECTRONIC IGNITION SYSTEM -- Late Model V6 & V8 5-35 SERVICING CHARGING SYSTEM Description 5-35 WITH INTEGRAL REGULA TOR Operation 5-36 MOTOROLA 6-28 Troubleshooting 5-36 Disassembling 6-31 Cleaning & Testing 6-31 ,. ELECTRICAL :> SERVICING CHARGING SYSTEM INTRODUCTION 6-1 WITH INTEGRAL REGULA TOR BATTERIES 6-1 VALEO 6-34 Construction 6-2 Troubleshooting 6-34 Location 6-2 Removal 6-35 Service 6-2 Cleaning & Testing Brushes 6-36 Jumper Cables 6-5 Alternator Testing 6-36 Storage 6-5 Assembling & Installation 6-39 Dual Ba ttery Installation 6-5 CRANKING SYSTEM 6-40 GAUGES AND LIGHTS 6-7 Troubleshooting 6-40 Constant Voltage System 6-7 Oil & Temp. Gauges 6-7 AUTOLITE CRANKING MOTOR 6-44 Warn ing Ugh ts 6-7 Disassembling 6-44 Thermomelt Sticks 6-8 Cleaning & Inspecting 6-45 Fuel Gauges 6-8 Bench Testing 6-45 Tachometer 6-10 Assembling 6-47 HORNS 6-11 PRESTOLITE CRANKING MOTOR 6-48 Disassembling 6-48 CHARGING SYSTEM 6-11 Cleaning & Inspecting 6-49 Alternator -- Description Assembling 6-49 and Operation 6-12 Alternator Protection BOSCH CRANKING MOTOR 6-51 During Service 6-13 Removal 6-51 Troubleshooting 6-13 Tests 6-52

© 2006 PDF Manual Master 6 ELECTRICAL (Continued) DUOPROP LOWER UNIT 8-63 BOSCH CRANKING MTR. (Cont.) Propeller Service 8-63 Disassembling 6-53 Propeller Removal 8-63 Cleaning & Inspecting 6-55 Propeller Installa tion 8-65 Assembling 6-56 Pre para tion for Service 8-67 Testing Completed Work 6-59 Disassembling 8-68 Installa tion 6-59 Cleaning & Inspecting 8-75 Assembling 8-77 DELCO CRANKING MOTOR 6-62 Shim Calculations 8-79 Servicing & Testing 6-62 Assembling Continues 8-83 Assembling 6-64 Checking Backlash 8-87 7 COOLING 9 TILT/TRIM DESCRIPTION 7-1 INTRODUCTION 9-1 "RAW" WATER STRAINER 7-4 Tilt 9-1 HEAT EXCHANGER 7-5 Trim 9-1 "RAW" WATER PUMP 7-7 TROUBLESHOOTING 9-2 THERMOSTAT 7-9 OIL COOLER 7-9 TILT SYSTEM SERVICE Removal & Disassembling 9-4 8 STERN DRIVE Cleaning & Inspec ling 9-9 Assembling & Installation 9-9 INTRODUCTION 8-1 Operation 8-1 TRIM SYSTEM SERVICE TROUBLESHOOTING 8-2 Removal & Disassembling 9-13 Stern Drive Noises 8-2 Cleaning & Inspec ting 9-14 Service Precau tions 8-3 Assembling & Installation 9-15 PROPELLER SERVICE 8-3 Removal 8-3 TRIM SENDER SERVICE "Frozen" Propeller 8-4 Replace Wire 9-16 Change Propeller Rotation 8-5 Retaining Pawl Adjustment 8-5 10 STEERING Propeller Installation 8-6 DESCRIPTION 10-1 STERN DRIVE SERVO VALVE ADJUSTMENT 10-3 Removal 8-8 POWER STEERING COOLER 10-4 Installation 8-10 POWER STEERING KIT 10-4 UPPER GEAR ASSEMBLY 8-12 11 MAINTENANCE Disassembling 8-13 Cleaning & Inspecting 8-19 IN-SEASON MAINTENANCE 11···1 Assembling 8-21 Before Starting - First Time 11-1 Every 2 Weeks 11-1 INTERMEDIATE HOUSING Every 50 Hours 11-1 Disassembling 8-36 Every 100 Hours 11-4 Cleaning & Inspecting 8-41 Retaining Pawl Adjustment 11-5 Assembling 8-42 OFF-SEASON STORAGE 11-5 PRE-SEASON PREPARATION 11-8 STANDARD PROPELLER ADJUSTING BOAT TRIM 11-10 LOWER UNIT 8-47 ADJUSTING TRIM TAB 11-10 Preparation 8-47 FIBERGLASS HULLS 11-10 Disassembling 8-48 BELOW WATERLINE SERVICE 11-11 Cleaning & Inspecting 8-52 Assembling 8-54 GIMBAL HOUSING -- EXPLODED EXTENSIONS 8-62 DRAWING 11-12

© 2006 PDF Manual Master APPENDIX Engine AQ190A & 240A A-49 METRIC CONVERSION CHART A-I DRILL SIZE CONVERSION CHART A-2 Complete AQ205, AQ21IA, AQ231, REPLACEMENTP5TONS AQ271C & AQ31lA & B A-50 AQ125 AND AQ145 ENGINES A-3 V ALVE ADJUSTING KIT Model 431 A-51 AQ125 AND AQ145 ENGINES A-3 TUNE-UP ADJUSTMENTS A-4 Instrument Panel AQ200AB & AQ290A with ammeter A-52 ENGINE SPECIFICATIONS 4-Cylinder OHC Engine AQ200AB, AQ225 AB, AQI20B, AQI25A, AQI40A, & AQ290A with ammeter A-53 AND AQ145A A-8 Instrument Panel AQ200AB, 4-Cylinder OHC & DOHC AQ225AB &. AQ290A with AQI25B, AQ131 A, AQI45B, voltmeter A-54 AQI5IA, AND AQ171A A-14 Engine AQ200AB, AQ225AB 4- & 6-Cylinder In-Line & AQ290A with voltmeter A-55 AQ105A, AQ1l5A, AQ130A, Complete AQ200C, AQ225C, B, C & D, AQ165A, and AQI70A, B &. C A-20 & AQ225A with ammeter A-56 GMC V6 AQ175A A-25 Complete AQ200C AQ225C, & AQ225A with voltmeter A-57 GMC V6 Model 431 A-28 GMC V6 305CID, 307CID, Instrument Panel AQ280A 350CID & 454CID A-32 & AQ225A A-58 Ford V8 AQ190A & AQ240A A-37 Engine AQ280A & AQ225A A-59 HOLLEY CARBURETOR SPECS. A-41 Complete Model 740 A-60 TORQUE SPECS. AQl90A Instrument Panel with ammeter AND AQ240A A-41 and with voltmeter -- AQ200D, AQ225D, AQ260A WIRE IDENTIFICATION DWGS. & D, AQ290A, and all other AQ105A, AQ115A, GMC V6, V8, and Ford V8 A-61 AQ130A, B, C, & D, AQ165A, & AQl70A A-42 Power Tilt -- USA A-62 Complete AQI20B, AQ125A Power Til t -- all except USA A-63 & B, AQ140A, AQ145A & B A-43 Power Trim -- Single Station Complete AQ131A, AQ151A with trim gauge and &B A-44 trim limit switch A-64 Complete AQ171A A-45 Power Trim -- Dual Station with trim gauge and Complete AQ175A A-46 trim limit switch A-65 Early Model AQ200D, AQ225D, Power Trim -- Late Type -- AND AQ255D A-47 Single Station with Instrument Panel AQ190A trim gauge and trim & AQ240A with voltmeter A-48 limit switch A-66

© 2006 PDF Manual Master 1 SAFETY 1-1 INTRODUCTION Your boat probably represents a sizeable investm ent f or you. In order to protect this investment and to receive the maximum amount of enjoyment from your boat it must be cared for properly while being used and when it is out of the water. Always store your boat with the bow higher than the stern and be sure to remove the transom drain plug and the inner hull drain plugs. If you use any type of cover to protect your boat, plastic, canvas, whatever, be sure to allow for some movement of air through the hull. Proper ventilation will assure evaporation of any condensation that may form due to changes in temperature and humidity. 1-2 CLEANING, WAXING, AND POLISHING Any boat should be washed with clear water after each use to remove surface dirt and any salt deposits from use in salt water. Regular rinsing will extend the time between waxing and polishing. It will also give you "pride of ownership", by having a sharp looking piece of equipment. Elbow grease, a mild detergent, and a brush will be required to remove stubborn dirt, oil, and other un- sightly deposits. Stay away from harsh abrasives or strong chemical cleaners. A white buffing com- pound can be used to restore the original gloss to a scratched, dull, or faded area. The finish of your boat should be thoroughly cleaned, buffed, and polished at least once The Spirit of Western Engine, powered by a modified Volvo Penta AQ290, 350 CID engine and equipped with a Volvo stock Model 280 stern drive, attained 110 mph, when driven by Mike Basso during endurance competition. The boat was clocked by radar on a measured course. The only change to the lower unit was slight streamlining to the leading edge. Safety is a prime consideration for racing teams competing in such high-performance events. The "Spirit" is owned by Western Engine Distributors, Santa Ana, California, Volvo Penta distributors for Southern Califomia and neighboring areas until mid 1987, when Volvo eliminated the "three tier" distribution system.

© 2006 PDF Manual Master 1-2 SAFETY Pride of Ownership This well-maintained boat, engine, stem drive, and trailer, reflect the owners pride in his/her equipment. The rewards are efficiency, economy, enjoyment, and safe boating. each season. Take care when buffing or polishing with a marine cleaner not to over- heat the surface you are working, because you will burn it. 1-3 CONTROLLING CORROSION Since man first started out on the water, corrosion on his craft has been his enemy. The first form was merely rot in the wood and then it was rust, followed by other forms of destructive corrosion in the more modern materials. One defense against corrosion is to use similar metals throughout Zincs used with the Volvo Penta stern drive units. The bar attaches to the underside of the transom shield and the ring is secured to the bearing housing ahead of the propeller. A neglected boat and stern drive. Such corrosion and marine growth will be costly to the owner and greatly reduce his boating enjoyment through poor performance. What a contrast with the equipment shown in the left column. the boat. Even though this is difficult to do in designing a new boat, particularly the undersides, similar metals should be used whenever and wherever possible. A second defense against corrosion is to insulate dissimilar metals. This can be done by using an exterior coating of Sea Skin or by insulating them with plastic or rubber gaskets. Using Zinc The proper amount of zinc attached to a boat is extremely important. The use of too much zinc can cause wood burning by plac- ing the metals close together and they be- come "hot". On the other hand, using too small a zinc plate will cause more rapid deterioration of the metal you are trying to protect. If in doubt, consider the fact that it is far better to replace the zincs than to replace planking or other expensive metal parts f rom having an excess of zinc. Two proper size zincs may be purchased from the local Volvo Penta marine dealer, as shown in the accompanying lllustration. A partially corroded zinc bar from the transom shield. An excellent example of how the inexpensive zincs are sacrificed to save more costly parts. The zincs should be checked regularly and changed when they show this much deterioration.

© 2006 PDF Manual Master A Volvo Penta spare parts kit includes a raw water pump impeller, set of spark plugs, condenser, V-belt for the alternator, and a fuse. Such a kit, sold at modest cost, could prove most valuable in an emergency situa- tion. A zinc bar and ring (lower right), and a spare oil filter (Zeft), might be added to the kit by the prudent boat owner. The bar attaches to the underside of the transom shield and the ring is secured to the double bearing housing ahead of the propeller. The other illustration on the previous page is an excellent example of how the inexpensive zincs are sacrificed to save more costly parts. The zincs should be checked regularly and changed when they show signs of deteriorating. 1-4 PROPELLERS As you know, the propeller is actually what moves the boat through the water. This is how it is done. The propeller oper- ates in water in much the manner as a wood screw does in wood. The propeller "bites" into the water as it rotates. Water passes between the blades and out to the rear in """I .. _--- 10" o o 0 o PROPELLERS 1-3 ITATION BURN Cavitation air bubbles formed at the propeller. Manufacturers are constantly fighting this problem, as explained in the text. the shape of a cone. The propeller "biting" through the water in much the same manner as a wood auger is what propels the boat. Ventilation Ventilation is the forming of voids in the wa ter just ahead of the propeller blades. Marine propUlsion designers are constantly fighting the battle against the formation of these voids due to excessive blade tip speed and engine wear. The voids may be filled with air or water vapor, or they may actually be a partial vacuum. Ventilation may be caused by installing a piece of equipment too close to the lower unit, such as the knot indicator pickup, depth sounder, or bait tank pickup. Rotation Propellers are manufactured as right- hand rotation (RH), and as left-hand rotation (LH). The standard propeller for Volvo Penta stem drive units is L.H. rotation. 21"

1968-1991 Volvo Penta Inboard and Stern Drive Service & Repair Manual

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