Clymer 1994-2000 Volvo Penta Stern Drive Boat Engine Repair Manual

Description

Is your Volvo Penta engine having trouble starting? Did you know that Volvo Penta fuel cells, fuel pumps are prone to clogging and overheating? This manual will show you how to troubleshoot and repair common problems with Volvo Penta engines and save a fortune from having to take your boat in for service.

This Clymer 1994-2000 Volvo Penta Stern Drive Boat Engine Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1994-2000 Volvo Penta stern drive boat engines including 3.0 GL, SX, 3.0 GS, SX, 4.3 GL, SX, 4.3 GL, DP, 4.3 GS, DP, 4.3 GS, SX, 4.3 Gi, SX, DP, 5.0 FL, DP, 5.0 FL, SX, 5.0 Fi, DP, 5.0 GL, SX, DP, 5.0 Fi, SX, 5.7 GL, DP, 5.7 GL, SX, 5.7 Gi, SX, 5.7 GSi, SX, DP, 5.7 GS, SX, DP, 5.8 FL, SX, 5.8 Fi, SX, 5.8 Fi, DP, 5.8 FSi, SX, 7.4 GL, DP, 7.4 Gi, SX, DP, 7.4 GSi, DPX, 8.2 GL, DPX, and 8.2 GSi, DPX Volvo Penta Stern Drive Boat Engines.

1994 1995 1996 1997 1998 1999
2000

Includes general information about each model, tools and techniques, troubleshooting, lubrication, maintenance and tune-up, storage, cooling system, 3.0 liter 4-cylinder engines, 4.3 liter V6, 5.0, 5.7, 7.4 and 8.2 liter V8 engines, 5.0 liter and 5.8 liter V8 engines, fuel delivery system, cooling system, electrical system, drive unit and upper gearcase, lower gearcase, intermediate housing and transom shield, power trim and tilt systems, steering system and complete wiring diagrams. Features 738 illustrated pages.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Propellers

CHAPTER TWO, TOOLS AND TECHNIQUES

Safety first, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic’s techniques

CHATPER THREE, TROUBLESHOOTING

Starting system, Charging system, Ignition system, Fuel system (carburetor models), Clymer quick tip, Fuel system (fuel injected 4.3 L, 5.0 L % 5.7 L engines), Fuel system (fuel injected 5.0 L & 5.8 L engines), Fuel system (fuel injected 7.4 L engines), Engine performance, Engine overheating, Engine oil pressure, Engine oil leaks, Engine noises, Stern drive unit

CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP

Preoperational checks, Starting checklist, Post-operational checks, Cooling system draining, Engine maintenance and lubrication, Steering service, Power trim, tilt service (SX models), Power trim, tilt service (DP and DPX models), Stern drive lubrications, Engine tune-up, Carburetor service

CHAPTER FIVE, LAY-UP, COOLING SYSTEM SERVICE AND FITTING OUT

Lay-up, Cooling system draining, Filling closed cooling system, Fitting out

CHAPTER SIX, 3.0 LITER 4-CYLINDER ENGINES

Engine serial number and code, Special tools, Gasket sealant, Replacement parts, Precautions, Engine removal, Engine installation, Disassembly checklists, Rocker arm cover, Intake, exhaust manifolds, Exhaust bellows and flapper valve, Rocker arm assemblies, Crankshaft pulley, harmonic balancer and hub, Timing gear cover and seal, Camshaft, Oil pan, Oil pump, Cylinder head, Valves and valve seats, Valve lifters, Piston, connecting rod assembly, Rear main oil seal, Crankshaft, Diver coupler and flywheel, Cylinder block, Core plug replacement

CHAPTER SEVEN, 4.3 LITER V6; 5.0, 5.7, 7.4 AND 8.2 LITER V8 ENGINES

Engine model and serial numbers, Special tools, Gasket sealant, Replacement parts, Precautions, Engine removal, Engine installation, Disassembly checklists, Valve covers, Intake manifold, Exhaust manifolds, Exhaust bellows and flapper valve, Rocker arms, Crankshaft pulley and harmonic balancer, Timing chain front cover and oil seal, Timing chain and sprockets, Balance shaft (V6 models), Camshaft, Oil pan, Oil pump, Cylinder head, Valves and valve seats, Valve lifters, Piston, connecting rod assembly, Rear main oil seal, Crankshaft, Drive coupler and flywheel, Cylinder block, Core plug replacment

CHAPTER EIGHT, 5.0 LITER AND 5.8 LITER V8 ENGINES

Engine model and serial numbers, Special tools, Gasket sealant, Replacement parts, Precautions, Engine removal, Engine installation, Disassembly checklist, Valve covers, Intake manifold, Exhaust manifolds, Exhaust bellows and flapper valve, Crankshaft pulley and vibration damper, Front cover and seal, Timing chain and sprockets, Rocker arm assemblies, Camshaft, Oil pan, Oil pump, Cylinder head, Valves and valve seats, Valve lifters, Piston, connecting rod assembly, Rear main oil seal, Crankshaft, Drive coupler and flywheel, Cylinder block, Core plug replacement

CHAPTER NINE, FUEL DELIVERY SYSTEMS

Flame arrestor, Fuel quality, Carburetor fundamentals, Carburetors, Fuel injection systems (gasoline engines), Troubleshooting, Multipoint fuel injection (5.0 and 5.8 L engines), Throttle body fuel injection (4.3, 5.0 and 5.7 L Gi and GSi models), Multipoint fuel injection (7.4 L Gi and GSi engines)

CHAPTER TEN, COOLING SYSTEM

Thermostat, Hose replacement, Engine circulating pump, Seawater pump, Drive belts, Closed cooling system maintenance, Standard cooling system maintenance, Oil cooler

CHAPTER ELEVEN, ELECTRICAL SYSTEMS

Battery, Charging system, Starting system, Ignition system, EST ignition, BID ignition, TFI-IV ignition, Ignition coil, Switches and connectors, Solenoids, Electrical protection

CHAPTER TWELVE, DRIVE UNIT AND UPPER GEARCASE

Drive unit identification, Drive unit operation, Drive unit gear ratio, High altitude operation, Service precautions, Corrosion control, Drive unit lubrication, Drive unit removal, installation, Universal joint service, Upper gearcase service (DP-C1, D1 and DPX models), Upper gearcase service SX and DP-S models, Shift housing service (all models)

CHAPTER THIRTEEN, LOWER GEARCASE

Lower gearcase identification, Lower gearcase operation, Service precautions, Corrosion control, Propellers, Lower gearcase service (DP-C1, D1 and DPX models), Lower gearcase (SX and DP-S models)

CHAPTER FOURTEEN, INTERMEDIATE HOUSING AND TRANSOM SHIELD (BRACKET)

Intermediate housing (DP-C1, D1 and DPX models), Transom shield (DP-C1, D1 and DPX models), Transom bracket (SX and DP-S models)

CHAPTER FIFTEEN, POWER TRIM AND TILT SYSTEMS

Power trim and tilt system (DP-C1, D1 and DPX models), Power trim and tilt system (SX and DP-S models)

CHAPTER SIXTEEN, STEERING SYSTEMS

Safety precautions, Mechanical steering system, Power steering system

CHAPTER SEVENTEEN, SUPPLEMENT

Fuel system, Low-pressure electric fuel pump, Electronic fuel injection (EFI) system, Ignition key switch, Diagnostic trouble codes, Engine sensors, Power trim system, Steering service, Engnie maintenance and lubrication, Lay-up, Intake manifold, Low-pressure electric fuel pump, Fuel pump relay, EFI system relay, Fuel cell, Throttle body, Intake plenum, fuel rail and injectors, Relieving fuel system pressure, Fuel pressure regulator, Crankshaft-driven seawater pump, Power trim and tilt system (SX and DP-S models), Specifications

INDEX

WIRING DIAGRAMS