PDF Workshop Manual Volvo Penta Electrical Ignition Fuel Systems - 3 MB
This workshop manual is a specialized guide for the electrical, ignition, and fuel systems of Volvo Penta engines.
It contains detailed wiring diagrams, troubleshooting charts, and repair procedures.
This is an indispensable resource for marine mechanics and boat owners who need to diagnose and fix complex system issues.
Keep your Volvo Penta engine running reliably and efficiently.
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--- Page 1 ---
Workshop Manual C
Electrical, Ignition, Fuel 2(0)
--- Page 3 ---
Replacement Parts
When replacement parts are required, always use genuine
Volvo Penta parts, or parts with equivalent characteristics, includ-
ing type, strength, and material. Failure to do so may result in prod-
uct malfunction and possible injury to the operator and/or passen-
gers.
Parts Catalogs
Parts catalogs contain exploded views showing the correct assembly of
all parts, as well as a complete listing of the parts for replacement. These
catalogs are helpful as a reference during disassembly and reassem-
bly, and are available from Volvo Penta parts order.
Special Service Tools
Volvo Penta has specially designed tools to simplify some of the disas-
sembly and assembly operations. These tools are illustrated in this Ser-
vice Manual, in many cases in actual use. All Volvo Penta special tools
can be ordered from Volvo Penta parts order. Individual purchasers of
Service Manuals must order Special Tools through an authorized dealer.
Product References, Illustrations & Specifications
Volvo Penta reserves the right to make changes at anytime, without
notice, in specifications and models and also to discontinue models.
The right is also reserved to change any specifications or parts at any
time without incurring any obligation to equip same on models manu-
factured prior to date of such change. All information, illustrations and
specifications contained in this manual are based on the latest product
information available at the time of printing. The right is reserved to
make changes at anytime without notice.
All photographs and illustrations used in this manual may not depict
actual models or equipment, but are intended as representative views
for reference only. The continuing accuracy of this manual cannot be
guaranteed.
Tuning The Engine
The purpose of an engine tune-up is to restore power and performance
that has been lost through wear, corrosion or deterioration of one or
more parts or components. In the normal operation of an engine, these
changes can take place gradually at a number of points, so that it is
seldom advisable to attempt an improvement in performance by correc-
tion of one or two items only. Time will be saved and more lasting re-
sults will be obtained by following a definite and thorough procedure of
analysis and correction of all items affecting power and performance.
Refer to the Engine Service Manual for all tune-up specifications.
Elect/eng Safety Related 1-5
--- Page 4 ---
Test Procedures - Audible Warning Switches (if equipped)
Oil Pressure Switch: The oil pressure audible warning switch is cali-
brated to make or break contact at 4 ± 2 PSI (27,6 ± 13,8 kPa). Use an
ohmmeter to make the following continuity checks. Replace the switch
if it fails either of these tests.
1. With the engine off and the switch wire disconnected, there should
be a full continuity (zero) reading between the switch terminal and en-
gine block.
2. With the engine running and switch wire disconnected, there should
be no continuity (infinity) reading between the switch terminal and en-
gine block.
Water Ternperature Switch: The water temperature audible warning
switch is calibrated to make or break contact at 200° ± 5° F (93° ± 5° C).
Attach an ohmmeter to the switch and make the following check. Re-
place the switch if it fails this test.
1. Immerse switch in a container of oil. Heat oil over a flameless source
and check temperature with a cooking thermometer.
2. Below the make/break temperature, the ohmmeter should show a no
continuity (infinity) reading. Above the make/break temperature, the ohm-
meter should show a full continuity (zero) reading.
Test Procedure - Audible Warning Horn (if equipped)
Under normal conditions, horn will sound when ignition is turned
on. Horn will continue to sound until engine is started and oil pressure
exceeds 4 ± 2 PSI (27,6 ± 13,8 kPa).
The dash mounted audible warning horn can be tested as follows. Re-
place the horn if it fails this test.
1. Turn ignition switch to the ON position. Do not start engine.
2. If horn does not sound, disconnect the lead at the water temperature
audible warning switch, and momentarily touch lead terminal to engine
block. If audible warning horn does not sound, horn is defective, or wir-
ing of switch-horn-ignition switch circuit has lost continuity.
3. Disconnect the lead at the oil pressure audible warning switch, and
momentarily touch lead terminal to engine block. If audible warning horn
does not sound, horn is defective, or wiring of switch-horn-ignition switch
circuit has lost continuity.
Elect/eng 1-15
--- Page 5 ---
Hard Starting - Cold Engine
Ask these questions first:
Has Engine Always Done This? Check:
• Carburetor choke operation and adjustment
• Fuel lines for obstructions
• For debris inside fuel tank
• See Fuel System section
Was Engine Used For A Long Time? Check:
• For clean external canister and carburetor fuel filters
• Empty carburetor float bowl due to evaporation
• Water in fuel due to condensation
• Fuel quality deterioration
• See Fuel System section
Is This A New Condition? Check:
• Carburetor choke operation and adjustment
• Carburetor accelerator pump
• Fuel system for leaks, dirt, or obstructions
• Engine timing and ignition system
• See General Information, Ignition System, Fuel Sys-
tem sections
• See Engine Service Manual
Hard Starting - Hot Engine
Ask these questions first:
Has Engine Always Done This? Check:
• Carburetor choke operation and adjustment
• See Fuel System section
Is This A New Condition? Check:
• Brand, type or octane of fuel
• Spark plugs
• Water in fuel
• Condition of battery and cables
• Starter motor for overheat damage
Did Engine Refuse To Start After Being Run? Check:
• Ignition system primary circuit
• Ignition coil/ignition module
• Engine timing
• Carburetor choke operation and adjustment
• See General Information, Ignition System, Fuel Sys-
tem sections
• See Engine Service Manual
Elect/eng 1-25
--- Page 6 ---
Section 2
Cranking System
Table of Contents
Cranking System Operation .............................................................. 2-2
Cranking System Problems ............................................................... 2-9
Starter Motor 2
Bench Test ....................................................................................... 2-5
Replacement .................................................................................... 2-6
Specifications ................................................................................ 2-10
Test Procedures .............................................................................. 2-2
Wiring Diagrams, Cranking Circuit ................................................... 2-7
Safety Warnings
Before working on any part of the electrical system, read the Safety
section at the end of this manual.
The original mounting, support and routing of electrical system
parts conform with U.S. Coast Guard requirements. It is important
to maintain the original mounting, support and routing after ser-
vicing the electrical system to prevent possible fire and explosion
in boat’s engine compartment.
Do not substitute automotive parts. Volvo Penta marine compo-
nents meet U.S. Coast Guard regulations for external ignition proof
operation and marine use. Volvo Penta marine components are
specially designed not to cause ignition of fuel vapors in the bilge
or engine compartment. The use of automotive parts can result in
fire and explosion.
Sealants, Lubricants and Adhesives
Black neoprene dip
Elect/eng 2-1
--- Page 7 ---
Section 3
Charging System
Table of Contents
Alternator Service
Assembly ....................................................................................... 3-15
Belt Tension ..................................................................................... 3-4
Disassembly .................................................................................. 3-10
Internal Diagram ............................................................................ 3-20
Replacement .................................................................................... 3-3
Specifications ................................................................................ 3-21
3
Testing Rectifier ............................................................................ 3-13
Charging System Problems ............................................................. 3-19
Circuit Diagrams ............................................................................... 3-17
Description .......................................................................................... 3-2
Troubleshooting
Alternator ......................................................................................... 3-5
Chart ................................................................................................. 3-8
Wire Harness Tests .......................................................................... 3-6
Safety Warnings
Before working on any part of the electrical system, read the Safety
section at the end of this manual.
The original mounting, support and routing of electrical system parts
conform with U.S. Coast Guard requirements. It is important to main-
tain the original mounting, support and routing after servicing the
electrical system to prevent possible fire and explosion in boat’s
engine compartment.
Do not substitute automotive parts. Volvo Penta marine components
meet U.S. Coast Guard regulations for external ignition proof opera-
tion and marine use. Volvo Penta marine components are specially
designed not to cause ignition of fuel vapors in the bilge or engine
compartment. The use of automotive parts can result in fire and
explosion.
Sealants, Lubricants and Adhesives
Black neoprene dip
Elect/eng 3-1
--- Page 8 ---
Rotor Removal
6 1. Set alternator with pulley side down. Insert a screwdriver on
each side of the housing. Pry from under the stator using any two lower
slots. Do not pry on coil wires.
7 2. Remove the stator and rear housing from the rotor assembly.
8 9 3. Use a soft jaw vise to hold the rotor armature. Remove the
pulley nut E , washer F , pulley G , tall spacer H and fan I from the
rotor shaft.
6
10 4. Using a plastic hammer, tap the top of the rotor shaft while lifting 45389
up on the front housing. Remove short spacer J and front bracket K .
7
45390
8
45391
9
45392
10
45397
Elect/eng 3-11
--- Page 9 ---
Specifications
Alternator - 65 Amp
Minimum Engine RPM for Alternator Output ................................................................................................. 400 RPM
Regulated voltage range ............................................................................................................................. 14.0 - 14.7
Amperage output ....................................................................................................................................................... 65
Regulator ........................................................................................................................................ Internal, solid state
Belt tension .......................................................................................................... 1/4-1/2 in. give with finger pressure
Output tests: ................................................................................. Load battery to obtain maximum alternator output
At 650 engine RPM ............................................................................................................ 20 amps approximately
At 1500 engine RPM ........................................................................................................................... 53 amps min.
At 2000+ engine RPM ......................................................................................................................... 56 amps min.
“L2” terminal voltage (engine running) ............................................................................................... 13.0 - 14.0 volts
“P” terminal voltage (engine running) ..................................................................................................... 6.5 - 7.5 volts
Capacitor capacity...................................................................................................................... 0.5 ± 0.1 microfarads
Elect/eng 3-21
--- Page 11 ---
DRC7514
Trim/Tilt Circuit
1 Black 9 White
2 Red 10 Relays
3 Black (Ribbed Wire) 11 Green
4 Red/Purple 12 Blue
5 20 Amp Fuse 13 Green/White
6 Purple 14 Blue/White
7 Brown/White 15 10 Amp Fuse
8 Trim Sending Unit 16 40 Amp Fuse
Elect/eng 4-9
--- Page 12 ---
5 6 7
34930 34931 25545
2. Direct beam of timing light onto timing grid. Loosen distributor clamp,
then turn distributor slowly by hand until timing mark is set at the appro-
priate timing figure. See Tune-up Specifications in the General Infor-
mation section of the Engine Service Manual.
3. Recheck timing mark; reset if necessary. Tighten clamp bolt.
4. Stop engine. Remove adaptor plug.
Ignition Coil Replacement
8
5 1. Remove ignition coil to distributor cap high tension lead E , two 25551
pin connector (purple and gray wires) F , and two pin connector (pink
and brown wires) G from the ignition coil.
6 2. Remove two screws H securing coil to engine block and re-
move ignition coil.
7 3. Place coil in a vise. Wear eye protection. Remove two
rivet heads I . Drive the rivets out of the coil. Save the bracket pieces
J .
8 4. Assemble the two bracket pieces J and the coil using two screws
and nuts K provided in the replacement ignition coil kit. Tighten screws 9
34942
securely.
9 5. Mount the coil assembly to the engine block. Secure with two
bolts H . Tighten to 20-25 ft. lbs. (27-34 N m).
•
10 6. Attach two pin connector (pink and brown wires) G to the coil as
shown. Attach two pin connector (purple and gray wires) F to the coil
as shown.
11 7. Apply marine EP/wheel bearing grease or equivalent to the high
tension lead terminal E and attach it to the ignition coil.
10
34943
11
34944
Elect/eng Safety Related 5-9
--- Page 13 ---
7. Distributor housing: Spark suppression screens must be
tightly in place.
Reassembly
1. Apply silicone grease to the bottom edge of the sensor/ignition mod-
ule.
2 2. Install sensor/ignition module assembly into the distributor hous-
ing and secure with two screws and lock washers B .
4
2 3. Rotate the engine until one of the trigger wheel teeth lines up 25146
with the mark on the sensor.
4 4. Adjust the sensor air gap by sliding the sensor in or out until an
0.008 in. (0,203 mm) measurement can be taken between the sensor
and the trigger wheel tooth. Tighten the sensor mounting screw A se-
curely.
1 5. Install the rotor making sure to align the notch in the distributor
shaft with the rotor. Push the rotor down until it seats.
6. Attach the purple distributor lead to the positive (+) terminal of the
ignition coil. Attach the black distributor lead to the negative (-) terminal
of the ignition coil. Coat the terminals with black neoprene dip.
7. Reinstall the distributor cap. Tighten screws securely to main-
tain external ignition proof characteristics. Replace any high tension
leads that were removed. Pay close attention to high tension lead routing
and firing order.
8. Check ignition timing as required. See Finish Timing procedure.
Distributor Installation
If the distributor has not been removed and the engine will run, continue
on to the Initial Timing procedure.
Engine Not Disturbed
Use this procedure if the rotor/housing/block relationship was
marked, and the crankshaft has not been rotated. If ignition/valve timing
relationship has been disrupted or engine has been cranked with dis-
tributor out, install distributor following Timing Out of Synch procedure.
Elect/eng Safety Related 6-7
--- Page 14 ---
Section 7
Fuel Systems – Carbureted Models
Table of Contents
Carburetor Operation .......................................................................... 7-3
Carburetor Replacement
3.0 GS Models ................................................................................. 7-12
4.3 GL Models ................................................................................. 7-12
5.0 GL Models ................................................................................. 7-12
5.7 GS Models ................................................................................. 7-12
Carburetor Service and Adjustments - 2V Models
3.0 GS Models ................................................................................. 7-11
4.3 GL Models ................................................................................. 7-11
5.0 GL Models ................................................................................. 7-11
5.7 GS Models ................................................................................. 7-11
Electric Fuel Pump - 4.3 GL, 5.0 GL, and 5.7 GS Models
Filter Bracket Replacement ........................................................... 7-28
Operation ......................................................................................... 7-24
Relay Ohmmeter Tests .................................................................... 7-33
Replacement ................................................................................... 7-25
Specifications ................................................................................. 7-30
Troubleshooting .............................................................................. 7-29
Wiring Diagram ............................................................................... 7-34 7
Fuel Filter Replacement ...................................................................... 7-6
3.0 GS Models ................................................................................... 7-6
Canister ............................................................................................. 7-7
Carburetor ......................................................................................... 7-7
Mechanical Fuel Pump and Vent Hose
3.0 GS Models ................................................................................... 7-4
Pressure Testing ........................................................................... 7-4
Replacement .................................................................................. 7-5
Specifications ................................................................................ 7-5
Vacuum Testing ............................................................................. 7-4
Sealants, Lubricants and Adhesives .................................................. 7-2
Specifications, Carburetor ................................................................. 7-37
Tanks, Lines, Valves, and Fittings ....................................................... 7-8
Tools Required ..................................................................................... 7-2
Torque Values - All Models ................................................................ 7-37
Troubleshooting
Boat Fuel System ............................................................................. 7-8
Carburetor ....................................................................................... 7-22
Engine Fuel System ....................................................................... 7-35
Elect/eng 7-1
--- Page 15 ---
Carburetor Service and Adjustments:
2V Models
3.0 GS Models
4.3 GL Models
5.0 GL Models
5.7 GS Models
Table of Contents
Adjustments
Accelerator Pump Clearance ....................................................... 7-20
Accelerator Pump Stroke ............................................................ 7-19
Choke Unloader ............................................................................ 7-21
Choke Vacuum Qualification ....................................................... 7-20
Electric Choke .............................................................................. 7-21
Float Level - 3.0 GS Models ......................................................... 7-19
Float Level - 4.3 GL, 5.0 GL, and 5.7 GS Models ........................ 7-19
Idle Mixture and Idle Speed ......................................................... 7-21
Carburetor
Assembly ...................................................................................... 7-16
Disassembly ................................................................................. 7-13
Replacement ................................................................................. 7-12
Specifications ................................................................................... 7-37
Torque Values ................................................................................... 7-37
Troubleshooting ............................................................................... 7-22
Safety Warnings
When replacement parts are required, use genuine Volvo Penta parts
or parts with equivalent characteristics including type, strength, and
material. Failure to do so may result in product malfunction and
possible injury to the operator and/or passengers.
After any fuel system maintenance or repairs, always check for leaks.
Always ensure backfire flame arrestor fins are undamaged, and ar-
restor is in place and secured before starting engine.
When adjusting a carburetor while the engine is running or being
cranked, use extreme care to avoid getting hands, fingers, or cloth-
ing caught in the alternator and water pump belts, pulleys, and
other moving parts.
Elect/eng 7-11
--- Page 16 ---
Electric Choke
The electric choke has an adjustment to control its opening rate. By
loosening the clamp screws that retain the thermostatic spring housing,
the housing can be turned to alter adjustment. Turning housing in a coun-
terclockwise direction will richen mixture and make choke stay on longer.
Turning spring housing in opposite direction (clockwise) will lean out
mixture and make choke come off sooner.
The electric choke cap is grounded with an external ground wire.
Make sure all ground components are clean and free of corrosion. 3
15313
3 1. Set choke so that index mark on choke cover D is aligned
relative to index marks on choke housing E as specified.
2. If a richer or leaner mixture during warmup period is desired, it can
be obtained by rotating thermostat cover one mark at a time. Never set
index mark on cover more than two graduations off specified setting.
Choke Unloader
4 1. Hold throttle valves in a wide open position. Insert correct size
drill between lower edge F of choke valve and inner wall of air horn.
2. Press finger lightly against choke control lever. A slight drag should 4
22386
be felt as drill is pulled out.
5 3. To adjust, bend tab G on throttle shaft kick-down lever until
correct opening has been obtained.
Idle Mixture and Idle Speed
1. Initially set idle mixture by turning idle mixture screws inward until
they are lightly seated, then turn screws outward the specified turns. Do
not turn screws tightly against seats. Both the screw tips and casting
seats may be damaged. Replace screws with damaged tips.
2. Final adjustments are made with engine running at operating tem- 5
11714
perature. Refer to Specifications for correct idle RPM.
3. Use a tachometer to make final adjustments. Turn idle mixture screws
inward until engine RPM begins to drop due to lean mixture. Back screws
out evenly and alternately until the best idle RPM is reached. If RPM
begins to drop (due to an overly rich mixture) before reaching the speci-
fied RPM, turn screws inward until maximum engine RPM and smooth-
ness is achieved.
4. Readjust idle speed as necessary. Always adjust idle speed last.
Elect/eng 7-21
--- Page 17 ---
Two other items that would require checking are the screens in each
end of the fuel pump body. This requires removal of the upper elbow
and the lower fuel filter adaptor. If screens cannot be sufficiently cleaned,
replace the fuel pump. The screens are not serviced separately.
Checking Boat Fuel System
The most common causes of failures in the boat fuel system are due to
line restrictions or air entry. Typical restrictions are:
• kinked, bent, or internally swollen fuel lines
• fuel lines and/or tank selector valve I.D.’s too small
• restricted or wrong anti-siphon valve
• cracked or blocked fuel pick-up or screen inside tank
• blocked tank vent
Air entry can occur at any point on the suction side of the fuel system.
Air in the fuel system is usually indicated by a pump humming or squeal-
ing noise.
Pump noise is caused by air being drawn through the fuel pump
gears, but is not always an indicator that something is wrong. Mo-
mentary noise has several causes that are not linked to fuel system
failures:
• pump may squeal for a short time upon start-up as air
is expelled
• if ambient temperatures are high, the engine compart-
ment will be subjected to hot operating conditions that
may create vapor in the fuel lines
• a hot engine after shutdown will go into a “hot soak”
condition that may produce fuel vapors
• the use of ethanol fuel will also aggravate this condition
as it’s more susceptible to vapor formation
All of these situations are temporary, but may produce vapor that would
cause pump noise. Pump noise that is continuous, and/or cannot be
attributed to any of these conditions, could be an indicator of fuel sys-
tem problems.
Elect/eng 7-31
--- Page 18 ---
Sterndrive Shift System
The Shift System starts
here at the remote control lever. . .
. . . and ends here at the propeller.
What's Most Important?
When the control lever is in Forward,
Neutral or Reverse position . .
. . . Shift mechanism must match
control lever position.
What Could Happen?
If . . . Neutral If . . . Forward
Forward
or
Reverse
Reverse
. . . Propeller is still powered (turning) . . . boat will move opposite
unknown to operator, or engine will to direction intended by operator.
start in gear, boat will move unexpectedly.
How Can Loss of Shift Control be Minimized? In pre-delivery inspection and when servicing . . .
Read, understand and follow manufacturers instructions.
Closely follow the warnings marked with ...
Assemble parts and make adjustments carefully . . .
Test your work. Don't guess. Make sure propeller does what the operator wants and
nothing else.
Safety
S-3