1999-2006 Volvo Penta 5.0GL 5.0GI 5.7GS 5.7GSI Sterndrive Engine Service & Repair Manual

i Engine/eng Contents General Information ......................................................... General Engine Mechanical - V6 and V8 Models ............. 3.0 GS Engines ................................................................. 4.3 GL, GS and Gi Engines ............................................... 5.0 GL, Gi, 5.7 GS and GSi Engines ................................. 7.4 Gi Engines ................................................................... 7.4 GSi and 8.2 GSi Engines ............................................ Steering System ................................................................ Throttle and Shift Control Systems ................................. Cooling Systems ............................................................... Engine Removal and Installation ..................................... Safety ................................................................................ 1 2 3 4 5 6 7 8 9 S 11 10

ii Engine/eng

iii Engine/eng M All stern drive system components must be matched for either single or dual engine installations. Failure to properly match engine, transom bracket and vertical drive will result in poor boat performance, and risk damage to engine and drive because of incorrect drive gear ratio. Model identification is located on the engine valve cover, and MUST corre- spond with the transom bracket and vertical drive numbers as listed in this document. • Engine Model Number 1 2 3 • Transom Bracket Model Number 4 • Vertical Drive Model Number 5 Model Identification DR1145 DR4282 DR6815 DR2058 DR4957 1 2 4 5 3

iv Engine/eng

1-1 Engine/eng Section 1 General Information Table of Contents 1 Battery Cable Requirements ........................................................... 1-40 Belt Adjustments Alternator ....................................................................................... 1-25 Power Steering .............................................................................. 1-26 Belt Tension ...................................................................................... 1-24 Compresion Pressure Limit Chart .................................................... 1-7 Conversion Charts Drill ................................................................................................. 1-42 Metric ............................................................................................. 1-41 Crankcase Oil ................................................................................... 1-11 Engine Break-in ................................................................................ 1-21 Engine Compression Testing ............................................................ 1-5 Engine Troubleshooting Guides ..................................................... 1-29 Gasolines Containing Alcohol ........................................................ 1-10 Gasoline Requirements ................................................................... 1-10 Intake Manifold Vacuum Testing ....................................................... 1-8 Introduction ........................................................................................ 1-2 20-Hour Check .................................................................................. 1-23 Off-Season Storage Preparations ................................................... 1-13 Oil Filter ............................................................................................. 1-12 Periodic Maintenance Chart ............................................................ 1-44 Positive Closed-Type Ventilation System ...................................... 1-27 Power Steering Fluid Level ............................................................. 1-13 Power Trim/Tilt Fluid Level .............................................................. 1-13 Preparation for Boating After Storage ............................................ 1-20 Steering System Lubrication ........................................................... 1-13 Submerged Engine ........................................................................... 1-23 Symbols ............................................................................................ 1-43 Torque Specifications, General ....................................................... 1-40 Troubleshooting - System Isolation ................................................ 1-28 Tune-up Specifications .................................................................... 1-36 Tuning the Engine .............................................................................. 1-5 Safety Warnings Before working on any part of a Volvo Penta stern drive, read the Safety section at the end of this manual.

1-2 Engine/eng Introduction This service manual is divided into sections concerning various systems and assemblies. Refer to the Contents to locate the section cov- ering the system or assembly requiring service. Each section title page has an additional listing that will describe the section’s 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 through- out the text. Since models are subject to change at any time, some photos may not depict actual product. Good Service Practice Service required for stern drives is generally one of three kinds: • Normal care and maintenance - which includes putting a new stern drive into operation, storing engines, 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. Do not operate engine out of water even momentarily. If operated in test tank, use proper test wheel. Failure to do so can damage supply pump, overheat engine, or allow excessive engine RPM.

1-3 Engine/eng 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 becom- ing 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. Inter- rupting a job to locate special tools or repair kits is a needless delay. 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, Let- ters and Promotions, Special Tools 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 write to the Volvo Penta Service Department for additional help. Always be sure to give complete information, including engine model number and serial number. When a brand-name product or specific tool is called for, another item may be used. However, the substitute must have equivalent characteristics, including type, strength, and material. You must determine if incorrect substitution could result in product malfunction and personal injury to anyone. To avoid hazards, equivalent products which are used must meet all current U.S. Coast Guard Safety Regulations and ABYC standards. Safety Related

1-4 Engine/eng Replacement Parts 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 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 re- assembly, and are available from 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 order from Volvo Penta Parts. Individual purchasers of Service Manu- als must order Special Tools through an authorized dealer. Product References, Illustrations & Specifications Volvo Penta reserves the right to make changes at anytime, without 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 manu- factured 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. Safety Related

1999-2006 Volvo Penta 5.0GL 5.0GI 5.7GS 5.7GSI Sterndrive Engine Service & Repair Manual

You're Reading a Preview

Recently Viewed