Volvo Penta HU series Manuel d'instructions

Z~ Safety Warning

This WorkshopManual will alert you to certain procedures that

must be done very carefully. If you ignore this information,

you could...

® injure yourself or people aroundyou

®Injure the boat operator, boat passengers,or

people around the boat

®Damagethe Volvo Penta product or its systems

Understand the following symbolsbefore proceeding:

Z~I Safety Warning

Alerts youto the possibility of dangerand

identifies information that will help pre-

ventinjuries.

identifies information that will help pre-

vent damageto machinery.

Appearsnext to information that controls

correct assembly and operation of the

product.

This WorkshopManual 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. Whencorrectly

serviced, the Volvo Penta product will be reliable and safe to

operate.

WhenVolvo Penta special tools are called for, use them.

Wherementioned, the tools are required to perform the service

procedure.

If you use service proceduresor service tools that are not

recommendedin this manual, YOUALONEmust decided if

your actions might injure people or damagethe Volvo Penta

product.

Contents

GeneralInformation........................................

3.0 Engine............... . .....................................

4.3, 5.7 Engines.......................... . ..................

5.0, 5.8 FLEngines........................................

5.0, 5.8 Fi Engines.........................................

7.4, 8.2 Engines.......................... ......... ......... .

SteeringSystems- SX....................................

ControlSystems- SX.....................................

Cooling Systems.... .... .................. .......... .........

Engine Removaland Installation - SX..............

Safety............... ..... ..................... . ..................

Thisworkshopmanualis oneof a set of ninethat coversVolvoPentastem

drive models.All nine bookscanbe orderedas a set fromVolvoPenta

Parts. OrderP/N 7788850-1.

Individual workshopmanualscovering these modelsare also available.

Orderthe following part numbersfrom VolvoPentaParts.

® P/N 7788851-9SXDfve Unit andTransomShield

Includes information on TransomShield, UpperGearUnit and LowerGear

Unit service; DriveUnit removalandinstallation; Propellers;andTrim/Tilt hy-

draulic operation.

® P/N 7788856-8 E~g/ne Components

Includes information on Engineservice andtroubleshooting; Engineremoval

andinstallation; Steering systems;Throttle andShift Comrolsystems;and

Cooling systems.

¯ P/N 7788857-6BectffcN &/gnit~n System

IncJudesservice andtroubleshootinginformationon Crankingsystems;Charging

systems;Trim/Tilt electrical systems;Ignition systems;andEngineandInstru-

ment widng diagrams.

¯ P/N 7788858-4Furl System

Includes service and troubleshooting information on all carburetor, MRand

TB! fuel systemsand related components.

¯ P/N 7788852-7MRL~’agno~Manual(5.0 R, 5.8 F~:Si) - Ford

Includes step by step troubleshooting proceduresfor all MFIFord related

componentsand wiring.

, P/N7788853-5TBIDiagimsti

c" Manual(4.3 G~5. 7 Gi) -

Containstroubleshootingproceduresfor all TBI GMmodelsandrelated corn-

ponents.

® P/N 77888550 SP and DPWorkshopManual

Includes UpperGearUnit andLowerGearUnit overhaulprocedures,installa-

tion andremoval.

, P/N 7788854-3MRDiagnostic Manual(7.4 Gi. Z4 G~) -

includes step by step troubleshooting proceduresfor all MFi GMrelated compo-

nents andwiring,

¯ P/N 7788859-0 DPX- Lower Unit Workshop Manual

includes specific information for repair andoverhaulof the DPXLowerunit and

Xact

TM steering systemsnot coveredin the SPand DPWorkshopmanual°

This Volvo Penta Stern Drive WorkshopManual

Covers The Following Volvo Penta "HU"Models

Engine Model Nr. Transom Shield

3.0 GS SX NPS 3868181 38682881SX-LIMITEDTRIM

3,0 GSSX 3868182 3868288/SX-LIMITED TRIM

4.3 GL SX 3868184 3868176/SX-C

4.3 GSSX 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 GSDP 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

7.4G|DP 3868335 38682991DP-S

" = export on!y H.A. = high altitude applications

DPX

Engine Model Number Transom Shield

7.4 GSi DPX-CA3868198 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/DP-C 112.30:1

3868002/DP-Cl!1.95:1

38680021DP-Cl/1.95:1

38680021DP-C1/1.95:1

38680021DP-C1/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-CI1 °68:1

3868023/DPX-C/1,78:1

3868020/DPX-C11.59:1

38660211DPX-CI1.68:1

3868023/DPX-CI1 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-CI1.66:11HoA.

3868160/SX-CI1.66:11H.A.

38681601SX.CI1.68:11H.A.

3868162/SX-C/1.51:l/H.A.

Options

3868008/DP-C1/2.30:1/H.A.

38680081DP-CII2.30:llH.A.

3868008/DP-C1/2.30:11H.A.

38680081DP-C1/2.30:l lH.A.

3868008/DP-Cl12.30: l lH.A.

38680221DP-D1/1.78:1

38680021DP-C1/1.95: I/H,A.

N.A.

This Volvo Penta Stern Drive WorkshopManual

Covers The Following Volvo Penta "NC" Models

SX"

Engine

3.0 GSSX NPS

3.0 GSSX

4.3 GL SX

4.3 GSSX

5.0 FL SX

5.0 Fi SX

6.7 Gi SX

5.8 FL SX

6.8 FSi SX

ModelNr. TransomShield Drive Unit

3868181 36684321SX-LIMITEDTRIM 38683961SX.CTI1.85:l

3868182 38684321SX-LIMITEDTRIM 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 ModelNr. TransomShield

4.3 GL DP 3868164 38684041SX/DP

4.3 GSDP 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

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.

Options

N.A.

N.Ao

N.A.

N.Ao

N.A.

38681651DPII.78

N.Ao

N,A.

Engine ModelNr. TransomShield

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

38680201DPX11.59:1

38680211DPX11,68:1

38680231DPXIt ,78:1

3868020/DPX11.59:1

38680211DPX11.68:1

38680231DPX11.78:1

Section 1

General Information

Table of Contents

Belt Adjustments

Alternator .................................... 1-24

Power Steering ................................ 1-22

Raw-water Pump............................... 1-24

Belt Tension .................................... 1-21

CompressionPressure Limit Chart ................... 1-7

conversion Charts

Drill ......................................... 1-39

Metric ....................................... 1-38

Crankcase Oil ................................... 1-9

Engine Break-in .................................. 1-18

Engine compression Testing ........................ 1-5

Engine Troubleshooting Guides ..................... 1-26

Gasolines Containing Alcohol ....................... 1-8

Gasoline Requirements ............................ 1-8

Introduction .................................... 1-2

Lubrication

Inspection Chart ............................... 1-41

Steering System ............................... 1-11

Off-Season Storage Preparations .................... 1-11

Oil Filter ....................................... t-10

PowerSteering Ruid Level ......................... 1-11

PowerTrim/Tilt Fluid Level - SXModels......... ...... 1-11

Preparation for Boating After Storage ................ 1-17

Submerged Engine ............................... 1-20

Symbols ....................................... %40

Torque Specifications, General ...................... 1-37

Troubleshooting - SystemIsolation .................. 1-25

Tune-up Specifications ............................ 1-33

Tuning the Engine ................................ 1-5

20-Hour Check .................................. 1-20

Safety Warning

Before working on anypart of an Volvo Penta®sterndrive, read

the section called Safety at the endof this manual.

introduction

This workshopmanualcoversVolvoPentastern drive models.It is

divided into sections concerning various systemsand assem-

blies. Refer to the Contentsto locate the section covering the

systemor assemblyrequiring service. Eachsection title pagehas

an additional listing that will describethe section’s contentsin

moredetail. Besure to readthe SafetySectionat the endof this

manual,andpay special attention to all safety warningsas they

appearthroughoutthe text. Sincemodelsare subject to changeat

any time, somephotosmaynot depict actual product.

GoodServicePractice

Servicerequired for VolvoPentastern drives is generally oneof

three kinds:

Normalcare andmaintenance-which includes putting a

newstern drive into operation, storing engines,lubrica-

tion, andcare underspecial operatingconditions suchas

salt water andcold weather.

eOperating malfunctions - due to improper engine or

drive mounting,propeller condition or size, boat condi-

tion, or the malfunctionof somepart of the engine. This

includes engineservicing proceduresto keepthe engine

in primeoperating condition.

¯Complete disassembly and overhaul - such as major

serviceor rebuilding a unit.

It is important to determine before disassemblyjust what the

trouble is andhowto correct it quickly, with minimumexpenseto

the owner.

Whenrepairing an assembly,the mostreliable wayto ensurea

goodjob is to do a completeoverhaul on that assembly,rather

than just to replace the badpart. Wearnot readily apparenton

other parts could causemalfunction soonafter the repair job.

Repairkits andseal kits contain all the parts neededto ensurea

completerepair, to eliminate guesswork,andto savetime.

Repair time can also be minimizedby the use of special tools.

Volvo Pentaspecial tools are designedto perform service pro-

ceduresunique to the product that cannot be completedusing

tools from other sources. They also speedrepair work to help

achieveservice fiat rate times. In somecases,the useof substi-

tute tools can damagethe part.

Donot operateengineout of water evenmomentarily,if

operatedin test tank, useproper test wheel.Failure to do so can

damageraw-water pump, overheat engine, or allow excessive

engine RPM.

Preparationfor Service

Properpreparationis extremelyhelpful for efficient servicework.

A cleanworkareaat the start of eachjob will minimizetools and

parts becomingmisplaced. Clean an engine that is excessively

dirty before work starts. Cleaning will occasionally uncover

trouble sources. Obtain tools, instruments andparts neededfor

the job beforeworkis started. Interrupting a job to locate special

tools or repair kits is a needlessdelay.

Z~ Useproper lifting andhandling equipment.Workingon stern

drives without proper equipmentcan cause damageand person-

al injury.

Alwaysuse clean fresh fuel whentesting engines. Troublescan

often betraced to the useof old or dirty fuel.

Service Policy

Whetherwithin or following the warrantyperiod, VolvoPentahas

a constantinterest in their products.

It is VolvoPenta’spolicy to provide dealers with service knowl-

edgeso they can give professional service demandedby today’s

consumer.TheVolvo PentaService Schools, frequent mailing of

ServiceBulletins, Letters andPromotions,Special Toolsandthis

WorkshopManualrepresent VolvoPenta’s efforts to assist deal-

ers in giving consumersthe best and most prompt service

possible. This WorkshopManualcovers all phasesof servicing

the VolvoPentastern drive unit. If a service question doesnot

appearto be answeredin this manual,youare invited to write to

the Volvo Penta Service Departmentfor additional help. Always

be sure to give completeinformation, including engine model

numberand serial number.

Besure that you are familiar with VolvoPenta’sWarranty.if you

haveany questions, write the VolvoPentaService Department.If

other than genuineVolvo Pentareplacementcomponentsor parts

are used, Volvo Penta mayrefuse subsequentwarranty claims

involving that engine.

Whena brand-nameproductor specific tool is called for, another

item maybe used. However,the substitute musthaveequivalent

characteristics, including type, strength, andmaterial. Youmust

determineif incorrect substitution could result in product mal-

function andpersonalinjury to anyone.Toavoid hazards,equiva-

lent products which are used mustmeetall current U.S. Coast

GuardSafety Regulations and ABYCstandards.

ReplacementParts

/~ Whenreplacementparts are required, always use genuine

VolvoPentaparts, or parts with equivalentcharacteristics, in-

cluding type, strength, andmaterial. Failure to do so mayresult

in productmalPdnclionandpossibleinjury to the operatorand/or

passengers.

Parts Catalogs

/~ Parts Catalogsare a goodsourceof information for ordering

parts. Theyare NOTa goodsource for disassemblyandreas-

semblyof the enginesand drives. Theexplodedviews in g-~

PartsCatalogsare for illustxal~on of parts only, not a sourceof

assemblyins~uctJons. Theworkshopmanualhas det=led infor-

mationandis the only sourceof inforn~on for disassemblyand

reassembly.

Fagure to fogow workshop manuai ~ and

cau~nsmayresult in dea~, pemonalinjury to

yourself or bystandersanddamagedequipment.

SpecialServiceTools

VolvoPentahasspecially designedtools to simplify disassembh/

andreassemblyoperations. Thesetools are illustrated in this

WorkshopManual.All VolvoPentaspecial tools can be ordered

from Volvo PentaParts Department.Non-dealerusers of Work-

shopManualsmustorder Special tools through andauthorized

VolvoPentaDealer.

ProductReferences,Illustrations andSpecificadons

VolvoPentareservesthe right to makechangesat anytime,with-

out notice, to specifications, models,andprocedures.Also, the

fight to changeany specifications or parts at anytime without

incurring any obligation to equip sameon modelsmanufactured

prior to date of suchchange.All information, illustrations and

specifications, containedin this manualare basedon the latest

productinformationavailableat the timeof printing. Theright is

reservedto makechangesat any time without notice.

Photographsandillustrations usedin this manualmaynot depict

actual modelsor equipment.Thecontinuing accuracyof this

manualcannot be guaranteed.

SafetyRelated 1-4

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