Volvo Penta Stern Drives 2001 - 2004

Clymer Owners Marine Service & Repair Manual

2001, 2002, 2003, 2004

by Clymer Staff

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Volvo Penta Stern Drives 2001 - 2004 - Front Cover

Front Cover

Front Cover

Rear Cover

Rear Cover

description

Volvo Penta Stern Drives 2001 - 2004 Clymer Owners Marine Service & Repair Manual Covers the following models:
● Volvo Penta 30GS, 3.0 litre in-line 4-cyl (135 HP) (2001-2004)
● Volvo Penta 43GL, 4.3 litre V-6 (160 HP) (2001-2004)
● Volvo Penta 43GI, 4.3 litre V-6 (180 HP) (2001-2004)
● Volvo Penta 43GXI, 4.3 litre V-6 (210 HP) (2001-2004)
● Volvo Penta 50GL, 5.0 litre V-8 (220 HP) (2001-2004)
● Volvo Penta 50GI, 5.0 litre V-8 (250 HP) (2001-2004)
● Volvo Penta 50GXI, 5.0 litre V-8 (270 HP) (2001-2004)
● Volvo Penta 57GS, 5.7 litre V-8 (225 HP) (2001-2004)
● Volvo Penta 57GS, 5.7 litre V-8 (250 HP) (2001-2004)
● Volvo Penta 57GSI, 5.7 litre V-8 (280 HP) (2001-2004)
● Volvo Penta 57GXI, 5.7 litre V-8 (320 HP) (2001-2004)
● Volvo Penta 81GI, 8.1 litre V-8 (375 HP) (2001-2004)
● Volvo Penta 81GXI, 8.1 litre V-8 (420 HP) (2001-2004)
● Volvo Penta DPX375, 8.1 litre V-8 (375 HP) (2001-2004)
● Volvo Penta DPX420, 8.1 litre V-8 (420 HP) (2001-2004)

Contents:
QUICK REFERENCE DATA

GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Model identification / Engine operation / Fasteners / Shop supplies / Galvanic corrosion / Propellers / Basic tools / Special tools / Precision measuring tools / Electrical component replacement / Electrical system fundamentals / Basic mechanical skills / Specifications

TROUBLESHOOTING
Electrical component replacement / Preliminary inspection / Electric starting system / Charging system / Ignition system / Basic fuel system troubleshooting / Carburetor fuel system / Electronic fuel injection (EFI) system / Diagnostic trouble codes / Power steering system / Power trim electrical system troubleshooting / Power trim hydraulic system troubleshooting / Cooling system troubleshooting / Warning system / Engine troubleshooting / Drive system / Specifications

LUBRICATION, MAINTENANCE AND TUNE-UP
Before each use / After each use / Lubrication / Engine oil and filter change / Drive unit lubricant change / Steering cable lubrication / Gimbal bearing lubrication / Engine coupling lubrication / Engine alignment check / Fuel system maintenance / Fuel requirements / Water-separating fuel filter service / Flame arrestor cleaning / PCV valve cleaning / Engine coolant / Tune-up / Compression test / Spark plugs / Carburetor adjustments / Ignition timing adjustment / Test running the engine / Submersion / Specifications

LAY-UP, WINTERIZING AND FITTING OUT
Lay-up / Winterizing / Fitting out / Specifications

CHAPTER FIVE / ADJUSTMENTS
Carburetor / Ignition timing / Shift cable and linkage / Throttle cable / Trim position sender and trim limit control module / Specifications

ENGINE
Removal installation / Engine alignment / Rocker arm cover / Valve adjustment / Placing the No. 1 piston at TDC / Lifter cover / Camshaft lobe lift measurement / Cylinder head / Rocker arm and pushrod / Flywheel housing / Drive coupler / Drive plate / Flywheel / Flywheel pilot bearing / Output drive shaft, seals and bearings / Oil pan pump / Harmonic balancer / Timing gear/chain cover / Timing chain and sprockets / Balance shaft / Camshaft and lifters / Piston and connecting rod / Rear main seal and rear main seal carrier / Crankshaft / Break-in procedure / Specifications

FUEL SYSTEMS
Fuel system service / Mechanical fuel pump / Low-pressure electric fuel pump / Carburetor / Electronic fuel injection (EFI) / Intake manifold / Specifications

COOLING AND EXHAUST SYSTEMS
Thermostat / Recirculation pump / Seawater pump / Oil and power steering fluid cooler / Exhaust elbow / Exhaust bellow and flapper valve / Exhaust tube and flapper valve / Exhaust manifold / Specifications

ELECTRICAL SYSTEM
Battery / Alternator / Starter motor and solenoid / Starter relay / Fuel pump relay / EFI system relay / Ignition system / Oil pressure sender / Oil pressure switch / Engine temperature sender / Engine temperature sensor / Engine overheat switch / Exhaust overheat switch / Intake air temperature sensor IAT / Throttle position sensor TPS / Idle air control motor IAC / Knock sensor / Knock sensor module / Engine control unit ECU / Warning horn replacement / Specifications

DRIVE UNIT
Drive unit service precautions / Drive unit identification / Drive unit operation / Drive unit gear ratio / High altitude operation / Outdrive service precautions / Sacrificial anodes / Shifting and propeller rotation / Propeller / Drive unit removal and installation / Upper drive shaft housing / Universal joint / Shift housing service / Pressure and vacuum test / Specifications

INTERMEDIATE HOUSING AND TRANSOM SHIELD/BRACKET
Intermediate housing operation and inspection / Intermediate housing and suspension fork / Transom shield and mounting collar / Transom bracket / Specifications

POWER TRIM SYSTEM
Trim relay / Trim switch fuse / Trim limit control module / Trim motor / Trim pump / Fluid reservoir / Fluid screen / Hydraulic pump / Relief valve / Trim cylinder / Trim hose / Trim position sender / Filling and bleeding the trim system / Specifications

STEERING SYSTEM
Safety precautions / Mechanical (manual) steering system / Power steering system / Specifications

COLOUR WIRING DIAGRAMS

Clymer marine manuals can save you money on maintenance and repair. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, all the way to complete teardown & rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 0892878983 (0-892-87898-3)
  • ISBN-13: 9780892878987 (978-0-892-87898-7)
  • Format: Softcover, 760 pages
  • Date Published: 12-2004

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