Volvo Penta HU series, Workshop Manual

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Page 2: ... 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 ...

Page 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 1995 Volvo Penta of the Americas Inc All Rights Reserved i ...

Page 4: ... systems Charging systems Trim Tilt electrical systems Ignition systems andEngine andInstru ment widng diagrams P N 7788858 4Furl System Includes service andtroubleshooting information on all carburetor MRand TB fuel systemsandrelated components P N 7788852 7MRL agno Manual 5 0 R 5 8 F Si Ford Includes step by step troubleshooting proceduresfor all MFIFord related components and wiring P N7788853 ...

Page 5: ...868198 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 D P C 112 30 1 3868008 ...

Page 6: ...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 38681631DPI2 30 38681641DPI1 95 3868164 DPll 95 38681641DP 1 95 38681641DPIl g5 3868164 DP 1 95 3868022 DP D111 78 1 38...

Page 7: ...line 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...

Page 8: ...of the engine This includes engineservicing proceduresto keepthe engine in primeoperating condition Completedisassembly and overhaul such as major serviceor rebuilding a unit It is important to determinebefore disassemblyjust whatthe trouble is andhowto correct it quickly with minimum expense to the owner When repairing an assembly the mostreliable wayto ensurea goodjob is to do a completeoverhaul...

Page 9: ...rviceBulletins Letters andPromotions SpecialToolsandthis Workshop Manualrepresent VolvoPenta s efforts to assist deal ers in giving consumersthe best and most prompt service possible This Workshop Manualcovers all phasesof servicing the VolvoPentastern drive unit If a service questiondoesnot appearto beanswered in this manual youare invited to write to the Volvo PentaService Department for additio...

Page 10: ...specially designed tools to simplify disassembh andreassembly operations Thesetools are illustrated in this Workshop Manual All VolvoPentaspecial tools canbe ordered from Volvo PentaParts Department Non dealerusers of Work shopManualsmustorder Special tools through andauthorized VolvoPentaDealer ProductReferences Illustrations andSpecificadons VolvoPentareservesthe right to make changes at anytime...

Page 11: ... onceeveryboatingseason preferably at the beginning of the seasonwhenboat is brought out of off season storage Components that affect powerand performancecan be divided into three groups e Components affecting compression Components affecting ignition eComponents affecting fuel system Procedures for performinga completeenginetune upwill be cov eredin this manual EngineCompression Tesling 1 Compres...

Page 12: ... lowestreadingcylinderis within 75 of the highestreading cylinder Example if the highest pressurereading was140psi 140 X 75 105 Therefore anycylinder readingless than105psi indicates valve piston or piston ring problems if oneor morecylinders readlow squirt approximately onetable spoon 25ml of engineoil in the cylinderswith the low readings Repeat test on the cylinders with low readings This is co...

Page 13: ...ying compres sion checkignition and fuel systemcomponents Spark Plugs Spark Plug Leads Distributor Cap Rotor ignition Coil High Tension Lead ignition Switch Circuit Wiring and Connectors ECM Fuel TankPickup and Screen Fuel TankVent Anti SiphonValve if equipped Fuel Octaneand Quality Boat Fuel Lines andValves ExternalEngineFuelFilter Fuel Pumpand Line CarburetorFuel Filter or Screen Carburetor Adju...

Page 14: ... lead addles Donot useleadedfuel as it may plug the fuel injecton Premium fuel containsinjector cleanersand other additives that protect the fuel systemandprovideoptimum per formance Theusepremium gradefuels in all modds is s onglyrecom mended To prevent gumformation and corrosion in the fuel system useFuelConditioner in the gasoline FuelConditioneris availablefrom your VolvoPentastemdrive dealer ...

Page 15: ... motoroil for APiService SG CD During the break in period 20 hours frequently check the oil level Somewhat higher oil consumption is normaluntil piston rings are seated Theoil level shouldbemaintained in the safe rangebetween the AddandFull markson the dipstick This rangerepresents approximately 1 liter 1 quart if it is necessary to addor change the motoroil usea quality oil with APIservice catego...

Page 16: ...d above SAE 30 0 F 18 C to 32 F 0 C SAE 20W 20 Below0 F 18 C SAE 10W Donot fill above full mark Overfilling results in highoperatingtern peratures foaming the oil mixingair in the oil loss of power and reduced enginelife 3 0 GS 3 5qts 3 3liters 4 3 GL GS andGi 4 0qts 3 8liters 5 0 FL 5 0qts 4 7liters 5 7 Gi 5 0qts 4 7Riters 5 8 FL 5 0qts 4 7I ers 5 0Fi 5 0qts 4 7liters 5 8Fi FSi 4 0qts 3 8liters 7...

Page 17: ... removing level fill plugbyplacing 8 ragoverthelevel fill plugto prevent residualpressure fromspraying oil 1 Withthe drive unit tilted full up slowly andcarefully remove thelevel fill plug 2 Check the fluid level Thefluid shouldbelevel with the bottom of thefill holewhen the drive unit is at full tilt If necessary add VolvoPentapower trim tilt steeringfluid Replace the level fill plug andtighten s...

Page 18: ...rged in water or an accessory flushing adaptor mustbe usedwhile operating engine When usinga flushing adaptor remove propeller before starting engineto preventaccidental contact with moving propeller If propeller is not removed personalinjury may result Step3 Change Drive Unit Lubricant Drainandrefill with fresh DuraPlus syntheticGL5gear oil Refer to Drive Unit WorkshopManual Step4 FogEngine Carbu...

Page 19: ... ne ra e orlower the bowto engine in a ho ontal plane This wi providefor complete drainageof blockandmani folds ff bowof boat is tu gher or lower than stern some water maybe trapped in the en ne Nockor mmdfoids Improperor incomp W drain ing mayresult in freeze d nageto the en e manifolds drive unit or other components FREEZE DAMAGE IS NOT COVEREDUNDER VOLVOPENTA S L M TED WARRANTY nPt3 Front Loose...

Page 20: ... FSi Models Front Disconnectthe lower water bypasshoseat large diameterof check valve Drainor blowout check valveandshort hoseto thermostathousing Drainor blowout longhoseto fuel reservoir 341O2 All 5 0 and5 11 Models Front Disconnectanddrain long hoseat thermostathousing Disconnect andrain large hoseat circulating pump Starboard Loosenclamp and removerubber hose Remove cylinder block petcockstem ...