Volvo Penta Fuel System Workshop Manual

Volvo Penta Fuel System Workshop Manual
Full download: http://manualplace.com/download/volvo-penta-fuel-system-workshop-manual/
This is the cut pages sample. Download all 196 page(s) at: ManualPlace.com
Z~ Safety Warning
This WorkshopManualwill alert you to certain proceduresthat

mustbe donevery carefully, if you ignore this information,
you could...
® injure yourself or peoplearoundyou

® injure the boat operator, boat passengers,or
people around the boat
® Damagethe Volvo Penta product or its systems
Understandthe following symbolsbefore proceeding:
Alerts youto the possibility of dangerand

Z~ Safety Warning identifies informationthat will help pre-
vent injuries.
identifies informationthat will help pre-
vent damageto machinery.
Appearsnext to information that controls
correct assemblyand operation of the
product.
This WorkshopManualis written for qualified, factory trained

service technicians familiar with the use of Volvo Penta special
tools.
This WorkshopManuaBtells 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.
WhenVoUvoPenta 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

recommended in this manual, YOUALONEmust decide if
your actions might injure people or damagethe Volvo Penta
product.
Contents
General information ..............................
Carbureted Fuel System ............................
7.4Gi MFi System .................................
7..4GSi and 8.2GSi MFi System ......................
4.3Gi, 5.0Gi, and 5. 7GSiTBi System.................
Safety Section ....................................
FuelSy,~/eng i
This workshop
manualis oneof a set of four that coversVolvoPentastern-
drive "BY"models.All four bookscanbe orderedas a set from VolvoPenta
Parts. OrderP/N 7797450-9.
Individual workshop manuals
coveringthesemodelsare also available. Or-
der the following part numbers
fromVolvoPentaParts.
¯P/N 7797451-7 Engine Components
includes informationon Engineservice and troubleshooting;Engineremoval
andinstallation; Steeringsystems;Throttle andShift Controlsystems;and
Cooling systems.
¯ P/N 7797452-5Electrical & Ignition System
Includesservice andtroubleshootinginformationon Crankingsystems;
Chargingsystems;Trim/Tilt electrical systems;Ignition systems;andEngine
and Instrumentwiring diagrams.
,P/N 7797453-3Fuel System
Includesserviceandtroubleshootinginformationon all carburetor,MFIand
TBI fuel systemsand related components.
¯P/N 7797454-1 EF! Diagnostic Manual GM
Containstroubleshootingprocedures
for all Electronic Fuel injected GM
modelsand related components.
¯ P/N 7797455-8SX and DP-SSterndrives and Transom
Shield
Includes information on Transom Shield, UpperGearUnit and LowerGear
Unit service;DriveUnit removalandinstallation; Propellers;andTrim/Tilt
hydraulicoperation.
This VolvoPentaWorkshopManualiis part of a set that
coversthe following VolvoPenta"BY"Models
Engine Steering Model Number TransomShield Drive Unit
3.0 GS Manual 30GSMBYCCE 3868844, 3868895 (1.97:1) SX-M

Manual 30GSMBYCCE 3868844 3868896 (2.18:1) SX-M
Power 30GSPBYCCE 3868844 3868895 (1.97:1) SX-M
Power 30GSPBYCCE 3868845 3868896 (2.t8:1) SX-M
4.3 GL Power 43GLPBYC 3868844 3868892 (1.66:1) SX-M

Power 43GLPBYC 3868844 3868893 (1.79:1) SX-M
Power 43GLPBYC 3868844 3868894 (1.89:1) SX-M
Power 43GLPBYC 3868844 3868913 (1.95:1) DP-SM
Power 43GLPBYC 3868846 3868892 (1.66:1) SX-M
Power 43GLPBYC 3868846 3868893 (1.79:1) SX-M
Power 43GLPBYC 3868846 3868894 (1.89:1) SX-M
4.3 GS Power 43GSJBYA 3868694 PJX-C1

Power 43GSPBYC 3868844 3868892 (1.66:1) SX-M
Power 43GSPBYC 3868844 3868893 (1.79:1) SX-M
Power 43GSPBYC 3868844 3868913 (1.95:1) DP-SM
Power 43GSPBYC 3868846 3868892 {1.66:1) SX-M
Power 43GSPBYC 3868846 3868893 (1.79:1} SX=M
Power 43GSPBYC 3868846 3868913 {1.95:1) DP-SM
4.3 Gi Power 43GIJBYA m 3868694 PJX-C1

Power 43GIPBYCCE 3868844 3868892 (1.66:1) SX-M
Power 43GIPBYCCE 3868844 3868913 (1.95:1) DP-SM
5.0 GL Power 50GLPBYC 3868844 3868891 (1.60:1) SX-M

Power 50GLPBYC 3868844 3868890 (1.51:l)SX-M
Power 50GLPBYC 3868846 3868891 (1.60:1) SX-M
Power 50GLPBYC 3868846 3868890 (1.51:1) SX-M
iii
This VolvoPentaWorkshop Manualis part of a set that
coversthe following VolvoPenta"BY"Models
Engine Steering Model Number Transom Shield Drive Unit
5.0 Gi Power 50GIPBYCCE 3868844 3868891 (1.60:1) SX-M

5.7 GS Power 57GSPBYC 3868844 3868889 (1.43:1) SX-M

Power 57GSPBYC 3868844 3868890 (1.51:1)SX-M
Power 57GSPBYC 3868846 3868889 (1.43:1) SX-M
Power 57GSPBYC 3868846 3868890 (1.51:1) SX-M
5.7 GSi Power 57GSIPBYCCE 3868844 3868889 (1.43:1) SX-M

Power 57GSIPBYCCE 3868844 3868912 (1.78:1) DP-SM
Power 57GSIPBYCCE 3868844 3868913 (1.95:11 DP-SM
Power 57GSIPBYCCE 3868846 3868889 (1.43:1) SX-M
7.4 Gi Power 74GIPBYCCE 3868844 3868889 (1.43:1) SX-M

Power 74GIPSYCCE 3868844 3868913 (1.95:1) DP-SM
7.4 GSi Power 74GSmPBYCCE 3868850 3888911 (1.68:l)DP-SM

8.2 GSi Power 82GSIPBYCCE 3868850 3868911 (1.68:t) DP-SM

Power 82GSIPSYOCE 3868850 3868912 (1.78:1) DP-SM
DPX 385 Xact DPX385XBYDCE 3868289 3868637 (1.59:1) DPX-S1

Xact DPX385XBYDCE 3868289 3868638 (1.68:1) DPX-S1
DPX 415 Xact DPX415XBYDCE 3868289 3868637 (1.59:1) DPX-S1

Xact DPX415XBYDCE 3868289 3868639 (1.78:1) DPX-St
iv
Section 1
General Information
Table of Contents
Conversion Charts
Metric .................................. 1=15
Drill .................................... 1-16
Gasolines Containing Alcohol ................. 1-6
Gasoline Requirements ...................... 1-5
introduction ................................ 1-2
Periodic MaintenanceChart .................. 1-18
Symbols .................................. 1 +17
Torque Specifications, General ............... 1-18
Troubleshooting - Engine Guides .............. 1-8
Troubleshooting - SystemIsolation ............. 1-7
Tuning the Engine ........................... 1-5
Safety Warning
Beforeworkingon anypart of a VolvoPentasterndrive,readthe

sectioncalled Safetyat the endof this manual.
Fuel Sysleng
1-1
Introduction
This service manualcovers "BY" modelVolvo PentaSterndrives. It is
divided into sections concerningvarious systemsand assemblies.
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 read the Safety Section at the endof this manual,andpay special
attention to all safety warningsas they appearthroughoutthe text.
Since modelsare subject to changeat any time, somephotos may
not depict actual product.
GoodService Practice
Servicerequired for an Volvo PentaStern Drive is generally oneof
three kinds:
¯ Normalcareandmaintenance - whichincPudesputting a new
stemdrive into operation,storingengines,lubrication, andcare
underspecialoperatingconditionssuchas salt waterandcold
weather=
¯ Operating malfunctions - dueto improperengineor drive
mounting,propellerconditionor size, boatcondition,or the
malfunctionof some part of the engine.Thisincludesengine
servicingprocedures to keepthe enginein primeoperating
condition.
¯ Complete disassembly andoverhaul- such as major service
or rebuildinga unit.
it is importantto determinebefore disassembly
just whatthe trouble
is andhowto correct it quickly, with minimumexpenseto the owner.
Whenrepairing an assembly,the mostreliable wayto ensurea good
job is to do a completeoverhaulon that assembly,rather than just to
replace the bad part. Wearnot readily apparenton other parts could
causemalfunctionsoonafter the repair job. Repairkits andseal kits
containall the parts neededto ensurea completerepair, to eliminate
guesswork,and to save time.
Repairtime can also be minimizedby the use of special tools. Volvo
Pentaspecial tools are designedto performservice procedures
uniqueto the productthat cannotbe completedusing tools from other
sources.Theyalso speedrepair workto help achieveservice flat rate
times. In somecases, the use of substitute tools can damage the
part.
Do not operate engineout of water evenmomentarily.If

operatedin a test tank, use the propertest wheel.Failure to do so can
damagewater pump,overheat engine, or allow excessive engine
RPM.
1-2 Fuel Sys/eng

Preparation for Service
Properpreparationis extremelyhelpful for efficient service work. A
clean workarea at the start of eachjob will minimizetools andparts
becoming misplaced.Cleanan enginethat is excessivelydirty Ic)efore
work starts. Cleaningwill occasionally uncovertrouble sources.
Obtain tools, instrumentsandparts neededfor the job before workis
started. Interruptinga job to locate specialtools or repair kits is a
needlessdelay.
Useproper lifting andhandling equipment.Workingon sterndrives
without proper equipmentcan causedamage and personal injury.
Alwaysuse clean, fresh fuel whentesting engines. Troublescan often
be tracedto the use,of old or dirty fuel.
Service Policy
Whetherwithin or following the warrantyperiod, VolvoPentahas a
constantinterest in its products.
It is a VolvoPentapolicy to provide dealers with service knowledge
so they can give professional service demanded by today’s con-
sumer.TheVolvo Pentaservice schools, frequent mailing of Service
andparts informationbulletins, letters andpromotions,special tools,
andthis service manualrepresentour continuingefforts to assist
dealers in giving consumers the best and mostpromptservice pos-
sible. This service manualcoversall phasesof servicing a Volvo
Pentasterndrive unit. If a service questiondoesnot appearto be
answered in this manual,you are invited to write to the VolvoPenta
Service Department for additional help. Alwaysbe sure to give com-
plete information, including enginemodelnumberand serial number.
Besure that you are familiar with the VolvoPentaWarrantystatement.
If you haveany questions, write the Volvo PentaService Department.
If other than genuineVolvo Pentareplacementcomponents or parts
are used, Volvo Penta mayrefuse subsequentwarranty claims in-
volving that engine.
When a brand-name productor specific tool is called for, anotheritem
maybe used. However,the substitute musthave equivalent charac-
teristics, including type, strength, andmaterial. Youmustdetermineif
incorrect substitution could result in productmalfunctionandpersonal
injury to anyone.To avoid hazards,equivalent productswhichare
used must meetall current USCoast GuardSafety Regulations and
ABYCstandards.
Volvo Penta Fuel System Workshop Manual
Full download: http://manualplace.com/download/volvo-penta-fuel-system-workshop-manual/
Replacement Parts
Whenreplacementparts are required, always use genuineVolvo
Pentaparts, or parts with equivalentcharacteristics, including type,
strength, andmaterial. Failure to do so mayresult in productmalfunc-
tion andpossible injury to the operatorand/or passengers.
Parts CataJogs
Parts Catalogs contain explodedviews showingthe correct assembly
of all parts, as well as a compaete
listing of the parts for replacement.
Thesecatalogs are helpful as a reference during disassemblyand
reassembly,and are available from Volvo Penta.
Special Service Tools
Volvo Pentahas specially designedtools to simplify someof the
disassemblyand assemblyoperations. Thesetools are illustrated in
this ServiceManual,in manycasesin actual use=All VolvoPenta
special tools can be orderedfrom Volvo PentaGenuineParts division.
individual purchasersof Service Manualsmust order Special Tools
throughan authorizeddealer.
Product References,illustrations & Specifications
Volvo Penta of the Americasreserves the right to makechangesat
anytime,without notice, in specifications andmodelsandalso to
discontinuemodels.Theright is also reservedto changeany specifi-
cations or parts at any time without incurring any obligation to equip
sameon modelsmanufacturedprior to date of such change.All
information, illustrations andspecifications containedin this manual
are basedon the latest productinformationavailable at the time of
printing. Theright is reservedto makechangesat anytimewithout
notice.
All photographs
andillustrations usedin this manualmaynot depict
actual modelsor equipment,but are intended as representative views
for referenceonly. Thecontinuing accuracyof this manualcannotbe
guaranteed.
//~ Safety Related 1-4 Fuel Sys/eng
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Volvo Penta Fuel System Workshop Manual

Full download: http://manualplace.com/download/volvo-penta-fuel-system-workshop-manual/

This WorkshopManualwill alert you to certain proceduresthat

® injure yourself or peoplearoundyou

Understandthe following symbolsbefore proceeding:

Alerts youto the possibility of dangerand

This WorkshopManualis written for qualified, factory trained

This WorkshopManuaBtells you how to correctly maintain and

WhenVoUvoPenta special tools are called for, use them.

if you use service proceduresor service tools that are not

General information ..............................

Carbureted Fuel System ............................

7.4Gi MFi System .................................

7..4GSi and 8.2GSi MFi System ......................

4.3Gi, 5.0Gi, and 5. 7GSiTBi System.................

Safety Section ....................................

Engine Steering Model Number TransomShield Drive Unit

3.0 GS Manual 30GSMBYCCE 3868844, 3868895 (1.97:1) SX-M

4.3 GL Power 43GLPBYC 3868844 3868892 (1.66:1) SX-M

4.3 GS Power 43GSJBYA 3868694 PJX-C1

4.3 Gi Power 43GIJBYA m 3868694 PJX-C1

5.0 GL Power 50GLPBYC 3868844 3868891 (1.60:1) SX-M

Engine Steering Model Number Transom Shield Drive Unit

5.0 Gi Power 50GIPBYCCE 3868844 3868891 (1.60:1) SX-M

5.7 GS Power 57GSPBYC 3868844 3868889 (1.43:1) SX-M

5.7 GSi Power 57GSIPBYCCE 3868844 3868889 (1.43:1) SX-M

7.4 Gi Power 74GIPBYCCE 3868844 3868889 (1.43:1) SX-M

7.4 GSi Power 74GSmPBYCCE 3868850 3888911 (1.68:l)DP-SM

8.2 GSi Power 82GSIPBYCCE 3868850 3868911 (1.68:t) DP-SM

DPX 385 Xact DPX385XBYDCE 3868289 3868637 (1.59:1) DPX-S1

DPX 415 Xact DPX415XBYDCE 3868289 3868637 (1.59:1) DPX-S1

Beforeworkingon anypart of a VolvoPentasterndrive,readthe

Do not operate engineout of water evenmomentarily.If

1-2 Fuel Sys/eng

//~ Safety Related 1-4 Fuel Sys/eng

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