Volvo Penta 5.0 GL GXi OSi 5.7 GL Gi GXi OSi OSXi GiL GXi Marine Engine Complete Workshop Service Repair Manual

Workshop Manual Engine 5.0GL-A/B/C/D/E 5.0GXi-A/B(F)/C(F)/D(F)/E(F) 5.0OSi-B(F)/C(F)/D(F)/E(F) 5.7GL-A/B/C/D/E 5.7Gi-A/B(F)/C(F)/D(F)/E(F) C 2(0) 5.7GXi-A/B/C(F)/D(F)/E(F)/F(F) 5.7OSi-A(F)/B(F)/C(F)/D(F)/E(F) 5.7OSXi-A(F)/B(F)/C(F)/D(F)/E(F) 5.7GiI-A/B/C/D/F 5.7GXi-A/B/C/D/F

VPA 7743372 10-2004 i General Information . . . . . . . . . . . . . . . . . . . 1 General Mechanical . . . . . . . . . . . . . . . . . . 27 Engine — 5.0 & 5.7 Liter . . . . . . . . . . . . . . 51 Steering System . . . . . . . . . . . . . . . . . . . . 163 Throttle & Shift Control System . . . . . . . 185 Cooling System . . . . . . . . . . . . . . . . . . . . 193 Engine Removal and Installation . . . . . . 213 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S

ii VPA 7743372 10-2004 Model Identification All stern drive system components must be matched for either single or dual engine installations. Failure to properly match engine, transom bracket and sterndrive 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, and MUST correspond with the transom shield and sterndrive numbers as listed in the Prod- uct Matrix sheet available separately. Engine Model Number All Engine Models GL Models Gi, GXi, OSi and OSXi Models 23282 23279 23280 23278 23282

VPA 7743372 10-2004 iii U L T R A • L O W M I S SI O N U T R A • L O W E M I S Emission Control Labels GLModels Gi, GXi, OSi and OSXi Models 23363 23364 23366 23365

iv VPA 7743372 10-2004 Transom Shield Model Number Location Sterndrive Model Number Location SX and DP-S XDP-B DR2058 DR4957 23281

General Information VPA 7743372 10-2004 1 Section 1: General Information Tuning the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine Compression Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Test Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ignition System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Intake Manifold Vacuum Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 Gasoline Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Gasoline Containing Alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Steering System Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power Trim/Tilt Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Off-Season Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Preparation for Boating After Storage . . . . . . . . . . . . . . . . . . . . 12 Engine Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Submerged Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Alternator Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power Steering Pump Belt Adjustment . . . . . . . . . . . . . . . . . 16 Positive Closed-Type Ventilation System . . . . . . . . . . . . . . . . . . 17 Troubleshooting - System Isolation . . . . . . . . . . . . . . . . . . . . . . 18 Engine Troubleshooting Guides . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine Cranks, But Will Not Start . . . . . . . . . . . . . . . . . . . . . . 20 Hard Starting - Cold Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hard Starting - Hot Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Engine Runs Rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Engine Noises and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engine Overheats - Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Engine Dies Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Engine Won’t Reach Operating RPM - Check: . . . . . . . . . . . . 24 Defective Engine Lubricating System . . . . . . . . . . . . . . . . . . . 24 Low Battery Voltage After Short Storage . . . . . . . . . . . . . . . . 24 This service manual is divided into sections concerning various sys- tems 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 sections contents in

General Information 2 VPA 7743372 10-2004 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 throughout 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 servic- ing 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. 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 becoming 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. Interrupting a job to locate special tools or repair kits is a needless delay. Caution! 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 Bulle- tins, Letters 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

General Information VPA 7743372 10-2004 3 give complete information, including engine model number and serial number. 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 reassembly, 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. The purpose of an engine tune-up is to restore power and performance that has been lost through wear, corrosion or deterioration of one or more parts or components. In the normal operation of an engine, these changes can take place gradually at a number of points, so that it is seldom advisable to attempt an improvement in performance by correction of one or two items only. Time will be saved and more lasting results will be obtained by following a definite and thor- ough procedure of analysis and correction of all items affecting power and performance. Economical, trouble-free operation can better be ensured if a complete tune-up is performed once every year, preferably in the spring. Com- ponents that affect power and performance can be divided into three groups: • Components affecting compression • Components affecting ignition • Components affecting fuel system Tuning the Engine Tune-up procedures should cover these groups in the order given. While the items affecting compression and ignition may be handled

General Information 4 VPA 7743372 10-2004 according to personal preference, correction of items in the fuel system group should not be attempted until all items affecting compression and ignition have been satisfactorily corrected. Most of the procedures for performing a complete engine tune-up will be covered in greater detail in this manual. This section will deal mainly with the order of procedures involved in tuning the engine. Engine Compression Testing During all work done around the engine, while the engine is running or being cranked, use extreme care to avoid getting fingers or clothing caught in any belts, pulleys, or other moving parts. 2. Visually inspect stern drive unit for leaks, missing parts or other obvious defects. Replace deteriorated parts. 3. Compression check: Proper compression is essential for good engine performance. An engine with low or uneven compression cannot be properly tuned. • Operate engine to normal operating temperature. Engine must not be started and run without water for cooling. • Remove any foreign matter from around spark plugs by blowing out with compressed air. • Remove and inspect all spark plugs. Install thread-type compression gauge in spark plug hole. • To Prevent Sparking: – Remove (grey) 2-wire connector, with purple and grey wires, at ignition coil. –With choke and/or throttle plates wide open, crank engine through at least four compression strokes. Test Conclusion The indicated compression pressures are considered normal if the lowest reading cylinder is within 75% of the highest. Example: If the highest pressure reading was 140 PSI, 75% of 140 is 105. Therefore, any cylinder reading less than 105 PSI indicates an improp- erly seated valve, worn valve guides, piston, cylinder, or worn or bro- ken piston rings. Any cylinder reading 105 PSI or greater is within specifications, and compression is considered normal. If one or more cylinders read low, squirt approximately one tablespoon of engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on the cylinders. 1. If compression improves considerably, the piston rings are at fault. 2. If compression does not improve, valves are sticking or seating poorly, or valve guides are worn. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the pistons does not increase the compression, the cause may be a cylinder head gasket leak between the cylinders. This problem could allow engine oil and/or coolant to enter the cylinders. It is recommended the following quick reference chart be used when checking cylinder compression pressures. The chart has been calculated so that the lowest reading number is 75% of the highest reading.

Volvo Penta 5.0 GL GXi OSi 5.7 GL Gi GXi OSi OSXi GiL GXi Marine Engine Complete Workshop Service Repair Manual

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