Z~ Safety Warning

This Workshop Manualwill alert you to certain proceduresthat

must be done very carefully, if you ignore this information,
you could...

® injure yourself or people around you

® injure the boat operator, boat passengers,or
peoplearoundthe boat
® Damagethe Vo~voPenta product or its systems

Understandthe following symbolsbefore proceeding:

Alerts you to the possibility of danger and

Z~ Safety Warning identifies informationthat wilJ henppre-
ventinjuries.
identifies informationthat will help pre-
vent damageto machinery.
Appears next to information that controls
correct assembly and operation of the
product.

This WorkshopManualis written for qualified, factory trained

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

This WorkshopManual telts 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.

WhenVolvo Penta 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

recommendedin this manual, YOUALONEmust decide if
your actions might injure people or damagethe Volvo Penta
product.
General information

Cranking System

Charging System

Trim/Tilt system - Electrical

Prestolite BID Ignition System ........................... U

7.4GL ignition system

GMEFI Electrical System

Elecrical Wiring Diagrams

Safety .................................................

© 1997Volvo Pent8 of the Americas, inc. All Rights reserved

i
This workshop
manualis oneof a set of eight that coversVolvoPenta
sterndrivemodels.All eight bookscanbe orderedas a set fromVolvoPenta
Parts. OrderP/N77973(;0-0.
Individual workshopmanuals
coveringthesemodelsare also available. Or-
der the followingpart numbers
fromVolvoPentaParts.
¯ P/N 7797361-8 Engine Components
Includesinformationon Engineserviceandtroubleshooting;Engineremoval
andinstallation; Steeringsystems;Throttle andShift Controlsystems;and
Coolingsystems.
¯ P/N 7797362-6 Electrical & ignition System
Includesserviceandtroubleshootinginformationon Crankingsystems;
Chargingsystems;Trim/Tilt electrical systems;Ignition systems;andEngine
andInstrumentwiring diagrams.
¯ P/N 7797363-4 Fuel System
Includesserviceandtroubleshooting
informationon all carburetor.MFIand
T81fuel systemsandrelated components.
. P/N 7797364-2 EF! Diagnostic Manual GM
Containstroubleshooting
procedures
for all ElectronicFuel Injected GM
modelsandrelated components.
¯ P/N 7797365-9 PJX WaterJet
Containsserviceinformationfor repair andoverhaulof the waterjetsystem.
¯ P/N7797366-7 DPX- Workshop Manual
hcludesspecific informationfor repair andoverhaulof the DPX
Sterndrive
andXactTM steering systems.
¯ P/N 7797367-5 SX and DP-S Sterndrives and Transom
Shield
Includes information on TransomShield, UpperGearUnit andLowerGear
Unit service;DriveUnit removal
andinstallation; Propellers;andTrim/Tilt
hydraulicoperation.
¯ P/N 7797368-3 SP and DP Workshop Manual
IncludesUpperGearUnit andLowerGearUnit overhaulprocedures,instal-
iation andremoval.
 This Volvo Penta WorkshopManual
Covers The Following Volvo Penta "LK" Models

Engine
3.0 LITER 4.3 LITER 7,4 LITER

30GSMLKD 3888646 43GLPLKD 3868618 74GLPLKD 3868626

30GSPLKD 3868647 43GSPLKD 3868619 74GiPLKDCE 3868627
43GiPLKDCE 3868620 74GSiPLKD 3868742

5.7 LITER 8.2 LITER

57GLPLKD 38,68621 82GSiPLKD 3888743

57GLPLKR 3868699
57GSPLKD 3868598
57GLiPLKDCE 3888732
57GiPLKDCE 3868623
57GSiPLKD 3868624
57GSiCPLKD 3868686

TransomShield __
SX=C1 38684O4
SX-CLT1 3868432
SX-C1AC 3868515
SX=C2AC 3868820

Sterndrive
SX-C1 1.43:1 3868392 DP-S 2.30:1 3868163 DPX-S1 1.59:1 3868637
SX-C1 1.51:1 3868393 DP-S 1.95:1 3868164 DPX-S1 1.68:1 3868638
SX-C1 1,60:1 3868394 DP-S 1.78:1 3868165 DPX-S1 1.78:1 3868639
SX°C1 1.66:1 3868395 DP-S 1.68:1 3868166
SX-CT1 1.97:1 3868397 DP-S1 2:30:1 3868601
SX-RT1 1.66:1 3868398 DP-S1 1.95:1 3868602
SX-RT2 1.68:1 3868587 DP-Sl 1.78:1 3868603
SX-C2 1.41:1 3868581 DP=S1 1.88:1 3868604
SX-C2 t .51:1 3868582
SXoC2 1.60:1 3868583
SX-C2 1.66:1 3888584
SX-C1 1.85:1 3888465
SX-RT1 2.18:1 3868333
SX-RT2 2.18:1 3868588

,Jet Drive == :

PJX-C 3868694
PJX-C1 3868694

iii
 e ¯ ~ ~ @O" e" . O

[~ All sterndrive systems must be matched for either single or dual

engineinstallations. Failure to properly matchengine, transombracket and
sterndrive will result in poor boat performance,and risk or damage
to the
engineand or drive becauseof incorrect drive gear ratio.

The modelidentification is located on the engine valve cover, and MUST

correspondwith the transombracket and sterndrive numbersas listed in this
document.
DRl145
¯ Engine Model Number [~ E~ [~]

¯ Transom Bracket Model Number

¯ Sterndrive Model Number

DR4282

DR4944

//--/~- ~ ..... -~~

DR2058

DR4~37
ElectJeng
 Section 1
General information Bill
Tableof Contents

Battery and Cables .......................................... 1-5

Circuit Protection ........................................... 1-9
Circuit Protectors and Locations ............................. 1 =10
ConnectorService
Amphenol.............................................. 1-t 6
Packard ................................................ 1-18
Conversion Charts
Drill .................................................... 1-28
Metric .................................................. 1-27
Ignition Switch ............................................ 1-15
Introduction ................................................ 1-2
Oil and Water Sending Units ................................. 1-11
Perodic MaintenanceChart .................................. 1-30
Relays .................................................... 1-8
Solenoids .................................................. 1-7
Spark Plugs and Leads ..................................... 1-13
Symbols .................................................. 1-29
TorqueSpecifications, General ............................... 1-30
T,Toubleshooting
SystemIsolation .......................................... 1-19
Engine Troubleshooting Guides............................. 1-20
Tachometer................................................ 1-15
Tuning the Engine ............................................ 1-4

/~ Safety Warnin!~

Beforeworkingon anypart of the electrical system,readthe sectioncalled

Safety at the end of this manual

Theoriginal mounting, support and routing of electrical systemparts

conformwith U.S. CoastGuardrequirements.It i:s importantto maintain
the original mounting,supportand routing after servicing the electrical
system to prevent possible fire and explosion in boat’s engine
cl~mpartment.

Do not substitute automotiveparts. Volvo Pentamarine components meet

U.S. CoastGuardregulations for external ignition proof operation and
marine use. Volvo Pentamarine components are specially designednot
to causeignition of fuel vaporsin the bilge or enginecompartment.The
useof automotiveparts canresult in fire andexplosion.
introduction
This service manualcoversVolvoPentaSterndrivemodels.It is divided into
sections concerningvarious systemsandassemblies.Refer to the Contentsto
locate the sectioncoveringthe systemor assembly requiring service. Eachsec-
tion title pagehasanadditionallisting that will describe
the section’scontentsin
moredetail. Besureto readthe SafetySectionat the endof this manual,andpay
specialattentionto all safety warnings as theyappearthroughout the text. Since
modelsare subject to changeat any time, somephotosmaynot depict actual
product.

GoodService Practice

Servicerequiredfor VolvoPentaSternddves
is generallyoneof three kinds:

Normalcare andmaintenance - which includes putting a new

stern drive into operation,storingengines,lubrication, andcare
underspecial operatingconditionssuchas sart waterandcold
weather.
Operating maffunctions - due to improperengineor drive
mounting,propeflerconditionor size, boatcondition,or the
maffunctionof somepart of the engine.This includesengine
servicing proceduresto keepthe enginein primeoperating
condition.
¯ Complete disassemblyandoverhaum
- such as major service
or rebuildinga unit.

It is importantto determine beforedisassemb{y

just whatthe trouble is andhow
to correct it quickly, with minimumexpense
to the owner.

Whenrepairing an assembly, the mostreliable wayto ensurea goodjob is to do

a complete overhaulon that assembly,rather than just to replacethe badpart.
Wearnot readily apparenton other parts couldcausemalfunctionsoonafter the
repair job. Repairkits andseal kits contain all the parts needed to ensurea
completerepair, to eliminateguesswork, andto savetime.

Repairtime canalso be minimizedby the useof special tools. VolvoPentaspe-

cial tools are designed
to performserviceproceduresuniqueto the productthat
cannotbe completedusing tools from other sources. Theyalso speedrepair
workto helpachieveserviceflat rate times.In some
cases,the useof substitute
tools candamage the part.

~Donot operate engine out of water even momentarily.If operated in

test tank, usepropertest wheel.Failure to do so candamage
waterpump,over-
heat engine,or aIIow excessiveengineRPM.

1-2 E[ect/eng
 Preparation for Service

Properpreparation is extremelyhelpful for efficient service work. A clean work

area at the start of each job will minimizetools and parts becomingmisplaced.
Cteanan enginethat is excessivelydirty before workstarts. Cleaningwill occa-
sionaJly uncovertrouble sources. Obtain tools, instruments and parts neededfor
the job before workis started. Interrupting a job to locate special tools or repair
kits is a needlessdelay.

Z.V~ Useproper lifting and handling equipment.Workingon stern drives with-

out proper equipment can cause damageand personal injury.

Alwaysuse clean fresh fuel whentesting engines. Troubles can often be traced
to the useof old or dirty fuel.

Service Policy

Whetherwithin or following the warranty period, Volvo Pentahas a constant in-

terest in their products.

It is a Volvo Pentapolicy to provide dealers with service knowledgeso they can

give professional service demanded by today’s consumer.The Volvo Penta Train-
ing Centers, frequent mailing of Service Bulletins, Lelters and Promotions,Spe-
cial Tools and this ServiceManualrepresentour continuing efforts to assist deal-
ers in giving consumersthe best and most promptservice possible. This Service
Manualcoversall phasesof servicing Volvo PentaSterndrives. tf a service ques-
tion doesnot appearto be answered in this manual,you are invited to write to the
Volvo PentaService Departmentfor additional help. Alwaysbe sure to give com-
plete information, including engine modelnumberand serial number.

Be sure that you are familiar with the Volvo Penta Warranty. If you have any
questions, write the Volvo PentaService Department.If other than genuineVolvo
Penta replacementcomponentsor parts are used, Volvo Penta mayrefuse sub-
sequentwarranty claims involving that engine.

Whena brand-nameproduct or specific tool is called for, another item maybe

used. However.the substitute must have equivalent characteristics, including
type, strength, and material. Youmustdetermineif incorrect substitution could
result in product malfunction and personal injury to anyone.To avoid hazards,
equivalent productswhich are used must meetall current U.S. CoastGuardSafety
Regulations and ABYCstandards.

E~,o~.~ ~ Safety Related 1-3

 ReplacementParts
/~ Whenreplacementparts are required, always use genuine Volvo Penta
parts, or parts with equivalentcharacteristics, includingtype, strength, and
material. Failure to do so mayresult in productmalfunction and possible
injury to the operator and/or passengers.

Parts Catalogs

Parts Catalogscontain explodedviews showingthe correct assemblyof all parts,

as well as a completelisting of the parts for replacement.Thesecatalogs are
available from Volvo Penta Parts. Individual purchasersof Parts Catalogs must
order Parts Catalogs through an authorized dealer.

Special Service Tools

Volvo Penta has specially designed tools to simplify someof the disassembly
and assemblyoperations. Thesetools are illustrated in this Service Manual,in
manycases in actual use. All Volvo Penta special tools can be ordered from
Volvo PentaParts. Individual purchasersof Service Manualsmust order Special
Tools through an authorized dealer.

ProductReferences,illustrations & Specifications

Volvo Penta of the Americas reserves the right to makechangesat anytime,

without notice, in specifications and modelsand also to discontinue models.The
right is also reservedto changeany specifications or parts at any time without
incurring any obligation to equip sameon modelsmanufacturedprior to date of
such change.All information, illustrations and specifications containedin this
manualare basedon the latest product information available at the time of print-
ing. Theright is reservedto makechangesat anytimewithout notice.

All photographsand illustrations usedin this manualmaynot depict actual mod-

els or equipment,but are intended as representative views for reference only.
The continuing accuracyof this manualcannot be guaranteed.

Tuning The Engine

The purposeof an engine tune-up is to restore powerand performancethat has
beenlost through wear, corrosion or deterioration of one or moreparts or compo-
nents. In the normaloperation of an engine, these changescan take place gradu-
ally at a numberof points, so that it is seldomadvisableto attempt an improve-
mentin performanceby correction of one or two items only. Timewill be saved
and morelasting results will be obtained by following a definite and thorough
procedureof analysis and correction of all items affecting powerand performance.
Refer to the EngineServiceManualfor all tune-up specifications.

Z~ Safety Related 1-4 ElecUeng

Battery and Cables

Special Tools Required: Battery Hydrometer

The primary function of the battery is to provide powerto operate

the starter motor. The battery also supplies powerto operate the
lights and other electrical equipment which may be used when
the engine is not running. On battery ignition systems, the
battery must supply the ignition current during the starting
period and during the time that the alternator is not producing a
sufficient charge to meet operating requirements.

Battery Requirements

The boat should be equipped with a 12 volt battery capable, of

handling all normat electrican needs. All GL and GSModlels
(except 7.4 GL): Werecommend a 360 ampcold cranking rating
0° F (-18° C), 115minutesreservecapacity rating at 80° F (27° C) as
a minimum. All Gi, GSi and 7.4 GL Models: Werecommenda 650
ampcold cranking rating of 0° F (-18 ° C), 165 minutes reserve
capacity rating at 80° F (27° C) as a minimum.A maintenancefree
battery is acceptable as long as it meets the minimumbattery
requirements.

Battery Maintenance

There are two things which must be done periodically in order to

obtain long life from a battery.

1. Theelectrolyte mustbe kept abovethe plates and separator~3at

all times. The liquid level should be brought up to the level
specified by the battery manufacturer. Acid should never be
added except whenit is definitely knownthat somehas been lost
by spilling, and then only by an experienced battery man.

L~ Battery electrol~e is a corrosive acid and shouldbe handled

with care. If electrolyte is spilled or splashedon anypart of ’the
body, immediately flush the exposedarea with liberal amounts
of water and obtain medicalaid as soonas possible.
[~ 2. Be sure that the battery is kept nearly at full charge at all
times. The state of charge should be checkedat frequent intervals
by makingspecific gravity readings with a battery hydrometer.It
is suggestedthat gravity readings and replacementof evaporated
water be made every two weeks. Should the gravity fall more
than 0.040 specific gravity belowa fully chargedgravity reading,
removethe battery and have it charged.

[~ Full charge specific gravity is 1.260 at 80° F (27° C). DR3201

Do not use a jumper cable and a booster battery to start

engine. Removebattery from boat and recharge. Fumesvented
during chargingbattery can lead to an explosion.

E[ectJeng ~ Safety Related 1-5

 GoodBattery Servicing Includes the Folrowing Nine Points:

1. Protect boat against acid damage.

2. Cleanbattery.

3. Inspect cables.

4. Cleanterminals.

5. Inspect hold-downs.

6. Inspect casingfor leaks.

7. Makehydrometertest.

8. Remove battery from boat for tests. Rechargebattery if less

than 3/4 charged.Makeload test.

9. Addwater.

If battery is not in a goodstate of chargeor if it usesan excessiveamountof

water, check the charging system.

Cleanthe battery and terminals with a solution of baking soda and water. This
will neutralize the acid on the battery. After washingwith this solution, flush top of
battery with clear water. Care must be taken whenwashingthe battery so that
the baking soda and water solution does not enter the battery cells.

Cable Requirements

Thebattery should be mountedas close to the engine as practical to cut downon

battery cable lengths. Follow the recommendationsbelow.

JAil Carbureted
Models] [_A./IEFIMoclels
j

¯ 0-10 Feet 1 Gauge ¯ 0-10 Feet O Gauge

¯ 10-15 Feet 2/0 Gauge .10-15 Feet 2/0 Gauge

¯ 15-20 Feet 3/0 Gauge ¯ 15-20 Feet 4/0 Gauge

~ These specifications do not apply to aluminum battery cables. Volvo

Penta does not recommend
the use of aluminumbattery cables.

Z~To prevent possible explosion or fire, do not substitute automotive

parts for the following marinecomponents: starter, alternator, distributor
andrelated ignition parts, spark plug leads, solenoids, carburetor(and re-
lated parts), fuel pumpor fuel filter canister. Thesecomponents havebeen
specifically designednot to emit fuel vaporsor to causeignition of fueJ
vaporsin the bilge.

Safety Related 1-6 EtecUeng

Solenoids
Special Service Tools Required: Test Light or Continuity Meter and Car-
bon Pile

Thepurposeof the solenoid assemblyis to performmechanicaljobs elec-

Iromagnetically.In the caseof the solenoidusedwith the starter, this job
consists of completingthe heavyelectrical circuit betweenthe battery and
the motor.

[_.~The solenoid is a completelysealed unit which consists of a plunger

@and contact disk assembly®, a coil winding ©, a contact disk return
spring @,and four terminals which protrude from the solenoid body. The
two larger terminals ~ are the battery and motor terminals, while the
smaller ones(~ are the switch control terminal, and terminal for sending
battery voltage to the ignition systemduring engine cranking. Grounding
is by an external groundwire in the engineharness,and internally (through
bracket).
t
[~ Recoat all electrical connections after reassemblywith Black Neo-
®
prene Dip. DR3196

In operation, whenthe ignition switch is cTosed,an electric current flows

throughthe coil winding, causingthe plunger and contact disk to be drawn
inward. Whendrawninward, the contact disk completesthe circuit be-
tweenthe battery, motor andignition terminals, allowing the battery cur-
rent to flow.

A return spring is located just belowthe contact disk. When the electrical
circuit as described aboveis completed,the spring is compressed by the
magneticpull on the plunger and contact disk. When the electrical circuit
is broken(ignition switch released), the magneticpull on the plunger and
contact disk dropsto zero. At this time, the compressed
return spring breaks
tqe circuit by pushingthe contact disk awayfrom the motor and battery
studs of the solenoid.

Inspection Procedure

The solenoid used with the starter motor has proven to be trouble free
under normaloperating conditions. Noperiodic service is required other
than a checkto ensurethat all connectionsare clean and tight.

Test Procedure

Beinga completelysealedunit, repair or troubleshootingof detail parts is

impractical. If a solenoid is suspectedof being inoperative, it should be
tested as follows.

[~ Ensure solenoid has a good ground. Grounding is done by a

groundwire in the engine wiring harnessand through the base.

Elecdeng 1 "7
FTI1. Connecta continuity light or ohmmeter
(~), set to high ohms,to the
two large terminals (~) of the solenoid.

[~ 2. Connecta carbon pile @in series with a battery (~) and reduce the
voltage to less than six volts. Connectbattery leads to the onesmall terminal
of the solenoid and the base.

3. Increase the voltage until the continuity meteror test light showsa com-
pleted circuit. Stopand note the voltagereading- it shouldbe betweensix and
eight volts. If the solenoidrequires morethan eight volts to completethe cir-
cuit it shouldbe replacedsince, in actual use,it maynot performsatisfactorily.

Service and Repair Procedure

/
None- replace a malfunctioningunit.

Relays

Special Service Tools Required: Ohmmeter

or Test Light

Thepurposeof the relay assemblyis to use a low amperage electrical circuit

to control a high amperagecircuit. Unthe caseof a relay usedin a starting
circuit, the low amperage
circuit from the key switch will control the high am- DR3202
peragecircuit fromthe battery to the starter motor.

inspection Procedure

Therelays usedin stern drive electrical circuits haveprovento be trouble free

undernormaloperating conditions. Noperiodic service is required. To prevent
corrosion, all terminals of the relay and socketshould be coveredwith Termi-
nal Grease.

Relay OhmmeterTests

~ Throughout this section two symbols are used to interpret electrical

DR2065
troubleshootingresults.

[~ This symbolindicates continuity or very low resistance.

E~] This symbolindicates no continuity or very high resistance (oo).

I-~ To avoid damagingcomponentsor troubleshooting equipment, dis-

connect the battery cables from the battery and removethe relays before
proceeding.

1. Usea continuity light or ohmmeter

calibrated on appropriate scale to test
9
continuity.
DR2066

1 "8 F._}ect/eng
 2. Connectmeter leads to relay terminals 87a and 30.

¯ The meter must show continuity.

[~ 3. Connect meter leads to relay terminals 87 and 30.

e The meter must show no continuity.

4. Calibrate an ohmmeteron appropriate scale and connect

the leads to relay terminals 85 and 86.

¯ The meter must show 70 - 100 ohms. DR2149

[~ 5. Connectmeter leads to relay terminals 87 and 30. Connect

a 12 volt source to relay terminals 85 and 86.

¯ The meter must show continuity.

6. Connect meter leads to relay terminals 87a and 30.

Connecta 12 volt source to relay terminals 85 and 86.

¯ The meter must show no continuity. /

7. Replacerelay if your test results vary.
DR2149

Circuit Protection
Z~ Do not attempt to connect or disconnect any part of the
electrical circuit while the engineis running.

Wheninstalling additional electrical accessories always use indi-

vidual fused circuits. Powertakeoff should be madeat a termh~al
strip poweredby auxiliary accessory wire and protected by a 30
amp (maximum)Ifuse.
DR2149

DR2149

DR2149
EJeo~enO~ Safety Related 1-9
Circuit Protectors and Locations

10 AmpCircuit Breaker*

Protectstrim switch. Located

on trim/tilt pump.

SFE 20 AmpFuse*

Protectsignition switch. Locatedunderdash.

12.5 Amp
Circuit Breaker1

Protectsignition module.Locatedat front of starboardhigh-riseexhaustelbow.

12.5 AmpCircuit Breaker2

Protectsfuel pump.Locatedat starboardfront of engine.

12.5 AmpCircuit Breaker3

Protectsignition/injector relay andECM.

Locatedat front of starboardhigh-rise exhaustelbow.

20 AmpCircuit Breaker3

Protectsfuel pumps.
Locatedat port front of engine.

50 AmpCircuit Breaker*

Protectstrim/tilt motor.Located
at front of starboardhigh-riseexhaustelbow.

50A~Circuit Breaker !

Protectsmainharness.Locatedat front of starboardhigh-rise exhaustelbow.

60 AmpCircu~Br~aker3

Protectsmainharness.Locatedat front of starboardhigh-rise exhaustelbow,

¯AIt Models

1- 7.4 GLModelsOnly
2 4.3 GL, GSModelsOnay

3 All Gi andGSiModelsOnly

! CarburetedModelsOnly
,Oil and Water SendingUnits
Special Tools Required: Ohmmeter

inspection Procedure

Check wiring and connections between senders and gauges.

Checkto see that senders are operating properly. Inspect orifice
in oil pressure sender for blockage.

0il PressureSender:To check oil gaugesenders, start engine a nd

run up from slow to fast. Observegauge. If reading is unsatisfac-
tory, check sender with an ohmmeter:

¯ 0 PSI... 227-257 ohms

¯ 40 PSI... 92-114 ohms

¯ 80 PSI... 21.5-49.5 ohms

RepUacesender with a newone if it fails the ohmmeterchecks.

Retest; if reading ~is still unsatisfactory, problemmaybe in gauge,
engine lubrication system or excessive bearing wear. Refer to
appropriate Engine Section, paragraph Oil PumpService.

To check gauge, disconnect wire at sender, turn ignition switch

on, and momentarily ground sender wire. Gaugeneedle will peg
at high side of scale if gaugeis operating properly.

Water TemperatureSender: To check water temperature senders,

remove sender from engine. Connect sender to a digital ohm-
meter. Immerse sender in a container of oil with a cooking
thermometer. Heat oil over a flameless source. Observe meter
and thermometer. Meter should indicate:

¯ 448 ohms+ 10%at 100° F (38° C)

¯ 128 ohms-+ 7.5% at 160° F (71° C)

e 46.6 ohms-+ 5%at 220° F (105° C)

Elect/eng 1- 11
Oil Pressure Switch: The oil pressure audible warning switch is
calibrated to makeor break contact at 4 -=- 2 PSI (27,6 - 13,8 kPa).
Use an ohmmeter to make the fol~ovving continuity checks.
Replacethe svvitch if it fails either of thesetests.

1. With the engine off and the switch wire disconnected, there
should be a rule continuity (zero} reading between the switch
terminal and engine block.

2. With the engine running and switch wire disconnected, there

should be no continuity (infinity} reading between the switch
terminal and engine block.

Water Temperature Switch: The water temperature audible

warningswitch is calibrated to makeor break contact at 200° °-=- 5
F (93° - 5° C). Attach an ohmmeterto the switch and makethe
following check. Replacethe switch if it fails this test.

1. immerseswitch 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 ohmmetershould showa full continuity (zero}
reading.

~ Under normal conditions, horn will sound whenignition is

turned on. Horn will continue to sound until engine is
started and oil pressureexceeds4 +_ 2 PSR(27,6 ___ 13,8 kPa).

The dash mountedaudible warning horn can be tested as follows.

Replacethe hornif it fails this test.

1. Turn ignition switch to the ONposition. 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 wiring of switch-horn-ignition switch circuit
has lost continuity.

3. Disconnectthe 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.

1-12 ElectJeng
Spark Plugs and Leads
Removaland inspection

1. To disconnect wires, twist and pull only on boot becau~se

pulling on wire maycause separation of the core of the wire.
Remove spark plugs using a %in. spark plug socket or a %in. box
wrench. Use care to avoid cracking the spark plug insulators.

2. Carefully inspect the insulators and electrodes of all spark

plugs. Replace any spark plug which has a cracked or broken
insulator or which has loose electrodes, if the insulator is worn
awayaround the center electrode, or the electrodes are burned or
worn, the spark p0ug is worn out and should be discarded. Spark
plugs which are in good condition, except for carbon or oxide
deposits, should be thoroughly cleaned and gapped.

3. Thespark plug wires are a special resistance type. Thecore is

carbon impregnated linen. This type wire is superior to copper
core wire in its resistance to cross-fire; however,it is moreeasily
damaged than copper core. For this reason, care must be taken so
that the spark plug wires are removedby pulling on the spark plug
boots rather than on the wire insulation. If the wire is stretched,
’the core maybe broken with no evidence of damageon the outer
insulation. If the core is broken,it will causemisfiring. In the case
of wire damage,it is necessary to replace the complete wire
assemblysince a satisfactory repair cannot be made.

4. Use an ohmmeterto test ignition leads for excessive high

resistance or an .open circuit. Proper resistance is 3,000-7,000
ohmsper foot.

5. Clean ignition wires with a cloth moistenedin kerosene,

and wipe dry. Bendwires to check for brittle, cracked or loose
insulation. Defectiveinsulationwill per.mitmisfiring, cross-firing,
or spark to ground,therefore defective wires mustbe replaced.

6. If the wires are in goodcondition, clean any terminals that are

corroded and replace any that are broken or distorted. Replace
any wires with broken or deteriorated cable nipples or spark plug
boots.

’Spark Plug Cleaning

Spark plugs which have carbon or oxide deposits should be

cleaned in a bla:;t type spark plug cleaner. Scraping with a
pointed tool will not properly remove the deposits and may
damage the insulator, if spark plugs havea wet or oily deposit, dip
them in a degreasing solvent and dry thoroughly with com-
pressed air. Oily plugs will cause the cleaning compound to p~tck
in the shell.
Carefully follow the instructions of the manufacturer
of the cleanerbeingused.
Cleaneachplug until the interior of shell andentire insulator is cleaned.Avoid
excessiveblasting.

1. Examineinterior of plug in goodlight. Remove any cleaning compound with

compressed air. If traces of carbonor oxideremainin plug, finish the cleaning
with a right blasting operation. Cleanfiring surfacesof center and side elec-
trodeswith severaPstrokesof a fine cut file.

2. Whenspark plugs havebeenthoroughly cleaned, carefully inspect themfor

cracks or other defects which maynot have beenvisible before cleaning.

Adjust Spark PnugGap

Usea round w~refeeler gaugeto checkthe gap betweenthe spark plug erec-
trodes. Flat feeler gaugeswill not give a correct measurement if the elec-
trodes are worn. Adjust gap by bendingthe side electrode only. Bendingthe
center eFectrodewill crack the insulator. Setting the spark plug gap to any _ ® ®
other specification in an attempt to improveidle or affect engineperformance
is not recommended.

Installation of SparkPlugs andWires

3.0GS Models [~ DR2448

® V-6 Models [~

® V-8 Models [~

For properengineperformance it is very important that the correct spark plugs

be used. When installing spark plugs, makesure that the threadsin the cyEin-
der headand all surfaces on plugs and in cylinder headsare clean. Tighten
spark plugs the specified amount.All enginesuse taperedseat plugs without
gaskets.

~Do not operate engine if spark plug boots or high tension leads are
DR2453
torn or cracked. This condition can allow external sparks which could
ignite any fuel vapors in the engine compartment.

Spark plug wires must be arranged betweenthe distributor cap and spark
plugs in the order of firing sequence.If spark plug wires are not correctly
installed, misfiring or cross-firingwill result.

Z~ Safety Related 1-14 ElecUeng

ignition Switch

Special Tools Required: Continuity Light or Meter

Inspection Procedure

Checkfor loose connections, loose or corrodedterminals. Checkfor cor-

rect wiring.

Test Procedure

~ Disconnect battery leads at battery and leads at switch.

¯ Connectcontinuity light or ohmmeter leads between

switch battery (B) terminal and ignition (A) terminal.
switch to ONposition. Light or metershould indicate
continuity.

, Connectcontinuity light or ohmmeterleads between

switch battery (B) terminal and starter (S) terminal.
switch to START position. Light or meter should indicate
continuity.

In the OFFposition, there should be no continuity betweenthe battery (B) DR3206

terminal andeither the ignition (A) or start (S) terminal. The(M) terminals
and (C) terminal are not usedin stern drive applications.

Service and Repair Procedure

Cleanterminals, correct wiring (see appropriate wiring diagramat end of

this section) or replaceunit. Tightenconnectionsand coat with Black Neo-
prene Dip, or equivalent.

Tachometer
SpeciaU Tools Required: None

inspection Procedure

1. Checkfor loose or corroded terminals and connectors.

2. Checktachometerfor tight connections,and trace leads for properrout-

ing. Determineif tachometeris programmed correctly for the engine.
Amphenol Connector Service
Terminal Removal
/
~Use the recommendedlubricant for terminal removal. Substitutes
maycause high resistance connectionsor short circuits betweenterminals,
or adverselyaffect the connectormaterial.

1. To removea terminal from the plug or receptacle, lubricate it by applying

isopropyl alcohol to both endsof the cavity.
DR4164
[~ 2. Select the proper removaltoot for the terminal:

@ Amphenol Pin Remover

(~) Volvo Penta Socket RemoverP/N 3854350-0

3. Place the plug or receptacle against the edgeof a flat surface and allow
clearance for the terminar to be removed.

m 4. Insert the removaltool into the terminal and pushthe terminal from the
connector.
30386
5. Pin © and socket @terminals maybe replaced if damaged.Crimp new
terminals onto the wire at point (~.

6. UseAmphenolCrimping Pliers whenattaching Amphenolterminals,

® I)R4541

30387

1- 16 ElectYeng
TerminalInstallation

1. Connectthe plug and receptacle before installing the terminals. Apply

isopropyl alcohor to the plug and receptacle. Align arrows and carefully
insert the plug into the receptacle.

2. Applyisopropyl alcohol to the terminal cavity.

E~ ~ use only Volvo Penta Insert Tool, P/N 3854349-2,to install termi-
nals. To avoid injury, securely hold insert tool against shoulderof
terminal while inserting terminals. 30388

r~ 3. Position the insert tool (E) against the shoulder@of the terminal.

[~ 4. Rest the connector against a solid surface. With the insert tool
firmly against its shoulder, insert the leading tip of the terminal into its
cawty.Pushthe terminal in until the step (~) of the insert tool reachesthe
connectorbody, seating the terminal.

[~ 5. Checkyour work. Separatethe connector and look at the terminal

you just installed. If it is properly seated,apply isopropyl alcohol to both
connectorhalves and reconnectthem. If the terminal did not seat, remove
~t and repeat the procedure. 3O389

[=~6. Securethe connector with wire retainer.

30390

30391

38392
E lectJeng ~ Safety Related 1-17
Packard ConnectorService
Terminal Removal

To removea terminal, its holding tab must first be compressed

enoughto clear the body of the connector whensliding out.

insert a thin wire, such as a paper clip, about 1/4 in. (6 ram}
into the slot next to the terminal to be removed.As the ,wire seats,
it will compressthe tab.

Gently pull the wire and slide its terminal out of the connector 23541
body.

Terminal Installation

[~ The tab on the terminal must extend out enoughto lock the
terminal in place inside the connector body. If the tab isn’t
extended, use a thin tool and bend it outward slightly.

insert the terminal into the connectorbodyuntil the tab locks into
place.

23540

1- 18 ElectJeng
Troubleshootbing
- Systemisolation
The following is to help you isolate a malfunction of one or possibly several systems. After determining
which systemsare related to the malfunction, refer to the individual systemtroubleshooting charts to
isolate the specific cause.

Engine shouldl crank at specified RPM.if not, check

for:
Cranking
System 1. Discharged or dead battery
2. Loose or corroded connections
3. Cranking System Troubleshooting Chart

Must have gocdspark at spark plugs. If not, check the:

Engine ignition 1. Distributor cap and rotor

Does Not System 2. Coil and spark plug leads
Run 3. Ignition timing
4. Automath: spark advance
5. ignition Troubleshooting Chart

Carburetor accelerator pumpshould squirt fuel into

venturi whenthrottle is advanced.If not, check the:
Fuel
System 1. Fuel tank, valves, and lines
2. Fuel pumpsand filter
3. Carburetor and filter
4. Boat Fuel System Troubleshooting Chart
5. Carburetor Troubleshooting Chart
6. Engine Fuel System Troubleshooting Chart

Checkthe following"

1. Compression
2. Ignition system
3. Fuel system
Engine Runs 4. Lubrication system
improperly 5. Cooling system
6. Vertical drive and propeller
7. Vertical drive gear ratio and installation
8. Engine Troubleshooting Guides
Engine TroubleshootingGuides (Non EFI)
EFI Engines: Refer to GMEFi Diagnostic Service Manual.

These guides were written to help you trace the symptomsof the
trouble to the source, without having to read through and prove
every possibility. Muchof the information here will be familiar to
well informed mechanics.

Also, manyfactors will seeminsignificant but whenyou think of

it, usually the toughest problemto troubleshoot is causedby the
smallest error. The greatest aid to solving a service problemis
information. Start gathering information from the boat operator
and write it on his job card or workticket. Find out pertinent facts,
such as:

¯ Whendid this trouble start?

e Howwas the boat loaded?
¯ Did the trouble occur suddenly, or start gradually?

Analyzethis information and try to matchit to similar situations

you have experienced in the past. Keepin mind the fundamentan
rules:

1. COMPRESSION
- Mixture inducted into cylinder and com-
pressed.

2. SPARK
- Proper intensity at the proper time.

3. FUEL- Proper mixture of air and fuel.

There are very old rules, but necessaryfor the engine to run. Use
these charts and the service information they refer to. Do not try
to remembertolerances, settings, measurements,etc., as they
are written in the service manual. Leaveyour mindfree to analyze
the problem.

Following is a list of the troubleshooting guides which maybe

found on the pages indicated.

Title .......................................... Page

1. Engine Will Not Crank .......................... 1-21

2. Engine Cranks, But Will Not Start ................. 1-21
3. Hard Starting - Cold Engine ...................... 1-22
4. Hard Starting - Hot Engine ...................... 1-22
5. Engine Runs Rough ............................ 1-23
6. Engine Noises and Vibrations .................... 1-23
7. Engine Overheats ............................. 1-24
8. Engine Dies Out ............................... 1-25
9. Engine Won’t Reach Operating RPM............... 1-25
10. Defective Engine Lubricating System .............. 1-26
11. Low Battery Voltage After Short Storage ........... 1-26
 Engine Will Not Crank

o Battery condition: weak, dead, sulfated, bad cells

o Battery cables for loose or corroded connections
® Shorted or open ignition switch
® Starter motor and solenoid for shorts, grounds or open
circuits
® Starter assist solenoid/relay
® Circuit breakers
® Wiring from battery to ignition switch
® See respective Cranking Systemsection

Engine Cranks, But Witl Not Start

o Primary circuit wiring from ignition switch to ignition

coil/ignition module
o Secondarycircuit wiring from coil to spark plug
o Spark plugs for proper gap, fouling, burned electrodes,
cracked or dirty insulator
o E.S.A. system, if so equipped, for improper activation
¯ See respective ignition Systemsection

® Quantity and condition of fuel in boat tank

o Operation and flow capacity of boat anti-siphon valve
o Fuel tank vent is unrestricted
® Fuel tank pick-up screen is clean
® Boat fuel lines are proper diameter for engine size, and
lines are unrestricted
® Fuel shutoff and multiple tank valves are open and
operating properly
e Fuel pumpvent hose for signs of fuel or oil that would
indicate a fuel pumpfaimure
o Fuel pumpoperation for correct vacuum and pressure
readings
® External fuel filter canister and carburetor for clean
filters
® Carburetor accelerator pumpfor fuel discharge
e See Fuel System manual

(~ 0 O = O =

¯ See Engine manual

EIect/eng 1-21
Hard Starting - Cold Engine

Ask these questions first:

e Carburetor choke operation and adjustment

e Fuel lines for obstructions
¯ For debris inside fuel tank
¯ See Fuea System manual

o For clean external canister and carburetor fuel filters

e Empty carburetor float bowl due to evaporation
e Water in fuel due to condensation
¯ Fuel quality deterioration
o See Fuel System manual

e Carburetor choke operation and adjustment

¯ Carburetor accelerator pump
¯ Fuel systemfor leaks, dirt, or obstructions
e Engine timing and ignition system
¯ See General Information, Ignition Systemsections
e See Fuel System, Engine Service manuaas

Hard Starting = Hot Engine

Ask these questions first:

¯ Carburetor choke operation and adjustment

® See Fuel System manual

¯ Brand, type or octane of fuel

® Spark plugs
® Water in fuel
¯ Condition of battery and cables
o Starter motor for overheat damage

Ignition systemprimary circuit

Ignition coil/ignition module
Engine timing
Carburetor choke operation and adjustment
¯ See General Information, ~gnition Systemsections
® See Fuel System, Engine Service manuals

1-22 Elect/eng
 Engine Runs Rough .......

® Idle speed and idle mixture

¯ Engine t~iming and spark plugs
® Fuel pump pressure
® Water or contaminants in fuel
¯ Carburetor or manifold vacuumleak
¯ Internal carburetor fuel leak
® See GeneraUinformation, ignition Systemsections
¯ See Fuel System, Engine Service manuals

o Air leak on suction side of fuel system

® Too low octane fuel
o Ignition systemsecondarycircuit
e Engine timing
¯ Wrongmodel or size carburetor, improper main jets or
powervalve, defective secondaryfuel circuit, secondary
vacuum,diaphragm failure
¯ External canister and carburetor fuel filters
® Fuel pump pressure
® Engine compression
¯ Wateror contaminantsin fuel, ,water in cylinders
¯ See General Information, Ignition Systemsections
® See Fuel System, Engine Service manuals

Engine Noises and Vibrations

¯ Rappingonly whenstarting (oil too heavy for prevaili’ng

weather, varnish on lifter, oil needsto be changed)
¯ Intermittent rapping (leakage at lifter checkball)
® Idle noise (excessive leak downrate, faulty check ball
seat)
® Generally noisy (excessive oil in crankcase, stuck lifter
plunger)
® Loudnoise at operating temperature(scored lifter plung-
er, fast leak downrate, oil viscosity too light for prev,ail-
ing weather or operating temperatures)
¯ See Engine manual

E|ectJeng 1-23
Engine Noises and Vibrations, Cent ...............
0 0 =
_ ~_ __ D II e

¯ Improper tuning
¯ incorrect spark plug wire routing
® Poor quality or contaminated fuel
¯ See General information, ignition Systemsections
¯ See Engine Service manual

¯ Water pumps
® Loosebelts, pulleys
¯ See Cooling System section of Engine manual

¯ Loose, broken or worn engine mounts

¯ Loose Uag screws holding mounts to stringer

¯ Loosebolt(s)

¯ Loose pulley, worn bearings

¯ Loose mounting bolts

¯ Failed U-joints or gimbal bearing

¯ Damagedinternal drive components
¯ Worn, bent or broken propeller hub or blades
¯ Loose, worn or damagedengine coupler

Engine Overheats- Check"

¯ Actual engine temperature by verifying with an accurate
thermometer
¯ Gaugeoperation and wiring circuit
e Sendingunit operation and wiring circuit
¯ Powerhead water pump and belt
¯ Water intake screens for blockage
e Thermostat
e Water supply hoses
e Engine timing
¯ Water leaks on pressure side of water supply pump
¯ Air leaks on suction side of water supply pump
¯ Engine compression
¯ See Engine Service manual.
Engine Dies Out ......

¯ Fuel gauge operation and wiring

¯ Fuel level in tank
o Wateror debris in fuel
e Fuel pickup tube and screen blockage
¯ Fuel tank vent blockage
o Pluggedexternal canister or carburetor fuel filters
¯ Air leak on suction side of fuel system
¯ Fuel leak on pressure side of fuel system
¯ Inoperative, restricted or incorrectly sized anti-siphon
vaI ve
® Boat fuel lines too small in diameter
¯ Fuel pumppressure and suction
® Carburetor cleanliness and operation
¯ See Fuel System manual

e S ® ® -

e Primary and secondary ignition circuits

¯ Ignition switch
e Circuit breakers
® Wiring between engine and dash
o Main engine harness wiring
® See General information and appropriate Ignition Sys-
tem sections

® Vertical clrive for internal damage

® Oil pressure gauge and crankcase oil level
® Temperature gauge and cooling system operation
® Internal engine componentsas required

Engine Won’t ReachOperating RPNI - Check:

¯ Fuel type or octane
¯ Propeller pitch or diameter, damagedblades, slipping
hub
¯ Crankcase oil volume
¯ Marine growth on hull and drive
¯ Wrongvertical drive gear ratio
¯ Operating at high altitude
e Restricted carburetor air intake
e Restricted exhaust outlets in engine, transom bracket or
drive
o Poor cylinder compression
o Carburetor size and type correct for engine
¯ Fuel pump pressure and vacuum
o Boat overloaded, or load improperly placed
¯ Engine overheating
¯ Engine timing and ignition system operation
e Remotecontrol cables and linkage for proper attachment
and travel
Defective EngineLubricating System

e Cloggedor incorrect oil filter

e Wornoil pumpgears, cover or shaft
¯ Wornor collapsed oil pumprelief valve spring, or foreign
material caught on valve seat
e Oil pumprelief valve plunger loose in cover
e Damagedfilter bypass grommet
e Clogged oil pickup screen, broken tube or housing
® Pluggedcrankshaft or block oil galleys
¯ Dirty or defective hydraulic lifters, clogged push rod
passages
¯ Poor quality, incorrect viscosity or quantity of oil
® Incorrect hose routing on remote filter systems
® Water in crankcaseoil from condensation, defective head
gasket, oil cooler, or cracked manifotd/btock water pas-
sages

0 D. " i ¯ | |[o * |a _ I " ¯

® Oil gauge/warning horn operation and wiring

® Engine temperature
® Oil pressure gauge and warning horn sender operation
and wiring

LowBattery Voltage After Short Storage - -

o " =-t’~,,.| ®- ie - _" "

® All electrical accessoriesincluding ignition circuit off

e Disconnect main battery negative cable from battery
¯ Connect ammeteror voltmeter in series between nega-
tive battery cable and negative battery post:
1. Meter reading of "’0" indicates no draw, test battery
and charging system
2. Meter movementno matter how slight indicates draw
from battery
¯ Disconnect main engine harness 10-Pin Connector:
1. Meter drops back to "0", problem caused by boat
system, continue to isolate eachboat electrical acces-
sory until problem is found
2. Meter does not drop back to "0", problem caused by
engine electrical system, continue to isolate each
engine electrical accessory until problemis found
e Repair or replace componentsas necessary

1-26 E(e~eng
 METRIC CONVERSIONCHART

;nches X 25.4 = millimetres (mm) foot-pounds X 1.3558 =: joules (j)

feet X 0.3048 = metres (m) calories X 4.187 = joules (j)
yards X 0.9144 = metres (m) Btu X 1055 ==joules (j)
miles X 1.6093 = kilometres (km) watt-hours X 3500 =: joules (j)
!nches X 2.54 = centimetres (cm) kilowatt - hrs X 3.600 = megajoules (M J)

o i A| 0
2
inches X 645.18 = millimetres 2 (ram
2) miles/gal X 0.42514 = kilometres/litre (kin/I)
2
inches X 6.452 = centimetres2 2)(cm
2
feet X 0.0929 = metres2 2)
(m N ote:
2
yards X 0.8361 = metres2 2)
(m 235o2/(mi/gal) == litres/100
acres X 0.4047 = hectares (104 2) 235.2/(litres/100 km) = mi/gal
(ha)
2
miles X 2.590 = kilometres2 (kin
2)
m
footcandles X 10.76 =: lumens/metres (Im/m
2)
3
inches X 1,6387 = milnimetres 3 3)
(mm
3
inches X 1,6.387 = centimetres3 3)
(cm
3
inches X 0.01839 = litres (I)
quarts X 0.94635 = litres (I)
gallons X 3.7854 = litres (I) inches HG(60°F) X 3.377 = kilopascais (kPa)
3
feet X 2’,8.317 = litres (I) pounds/sq in X 6.895 = kilopascals (kPa)
3
feet × 0,02832 = metres3 3) (m inches H20 (60°F) X 0.2488 = kilopascals (kPa)
fluid oz X 29.57 = millilitres (ml) bars X 100 = kilopascals (kPa)
3
yards X 0,7646 = metres3 (m 3) pounds/sq ft X 47.88 = pascals (Pa)

ounces (av) X 28.35 = grams (g) horsepower X 0.746 = kilowatts (kW)

pounds (av) X 0,4536 = kilograms (kg) ft-lbf/min X 0.0226 = watts (W)
tons (2000 Ib) X 907.18 = kilograms (kg)
tons (2000 Ib) X 0,90718 = metric tons (t)

°Celsius = 0.556 X (°F -32)

ounces= f (av) X 0,278 = newtons (N) °Fahrenheit = (1.8 X °C) +32
pounds- f (av) X 4,,448 = newtons (N)
kilograms - f X 9,807 = newtons (N)

pound-inches X 0.11299 = newton-metres (N.m)

2
~eet/sec X 0,,3048 = metres/sec2 ~)
(m/S pound-feet X 1.3558 = newton-metres (N.m)
2
inches/see X 0,,0254 = metres/sec2 2)
(m/S

miles/hour X 1.6093 = kilometres/hour (kin/h)

feet/sec X 0.3048 = metres/sec (m/s)
kilometres/hr X 0.27778 = metres/sec (m/s)
miles/hour X 0.4470 = metres/sec (m/s)

1-27
 Drill Size ConversionChart
SHOWINGMiLLiMETERSIZES, FRACTIONAL AND
DECIMALiNCH SIZES ANDNUMBERDRILL SIZES

Milli- Dec. Frac- Num- Milli- Dec. Frac- Num-Milmi- Dec. Frac- Num- Milli- Dec. Frac- Num-! Milli- Dec. Frac°
Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Eq~riv. tional ber Meter Equiv. tional

.1 .0039 1.75 .0689 .... 1570 22 6.8 .2677 10.72 .4219 2%4
.15 .0059 .... 0700 50 4.0 .1575 6.9 .2716 11.0 .4330
.2 .0079 1.8 .0709 .... 1590 21 .... 2720 i 11.11 .4375 ¾6
.25 .0098 1.85 .0728 .... 1610 20 7.0 .2756 11.5 .4528
.3 .0118 .... 0730 49 4.1 .1614 .... 2770 J 11.51 .4531 29/64
.... 0135 80 1.9 .0748 4.2 .1654 7.1 .2795 11.91 .4687 W32
.35 .0138 .... 0760 48 .... 1680 19 .... 2811 K 12.0 .4724
.... 0415 79 1.95 .0767 4.25 .1673 7.14 .2812 9/32 ... 12.30 .4843 3V64
.39 .0156 1/64 ... 1.98 .0781 %4 ... 4.3 .1693 7.2 .2835 12.5 .4921
.4 .0157 .... 0785 47 .... .1695 18 7.25 .2854 ~12.7 .5000 1/2
.... 0160 78 2.0 .0787 ’4.37 .1719 W~ 7.3 .2874 13.0 .5118
.45 .0177 2.05 .0807 .... 1730 1"7" .... 2900 L 13.10 .5156 3%4
.... 0180 77 .... 0810 46 4.4 .1732 7.4 .2913 13.49 .5312 17/32
.5 .0197 .... 0820 45 .... 1770 16 .... 2950 M 13.5 .5315
.... 0200 76 2.1 .0827 4.5 .1771 7.5 .2953 13.89 .5469 3%4
.... 0210 75 2.15 .0846 .... 1800 15 7.54 .2968 19/64 ... 14.0 .5512
.55 .0217 .... 0880 44 4.6 .1811 7.6 .2992 14.29 .5624 ~6
.... 0225 74 2.2 .0866 .... 1820 14 .... 3020 N 14.5 .5709
.6 .0236 2.25 .0855 4.7 .1850 13 7.7 .3031 14.88 .5781 37/64
.... 0240 73 .... 0890 43 4.75 .1870 7.75 .3051 ’15.0 .5906
.... 0250 72 2.3 .0905 4.76 .1875 ~s 7.8 .3071 15.08 .5937 19/32
.85 .0256 2.35 .0925 4.8 .1890 1"2’ 7.9 3110 15.48 3094 3%4
.... 0260 71 .0935 42 .... 1910 11 7.94 .3125 m6 ... 15.5 .6102
.... 0280 70 2.38 .0937 %2 ... 4.9 .1929 8.0 .3150 15.88 .6250 %
.7 .0276 2.4 .0945 .... 1935 10 .... 3160 O 16.0 .6299
.... 0292 69 .... 0960 41 .... 1960 9 8.1 .3189 16.27 .6406 41/64
.75 .0295 2.45 .0964 5.0 .1968 8.2 3228 16.5 .6496
.... 0310 68 .... 0980 40 .... 1990 8 .... 3230 P 16.67 .6562 21/32
J9 .0312 ½2 ... 2.5 .0984 5.1 .2008 8.25 .3248 17.0 .6693
.8 .0315 .... 0995 39 .... 2010 7 8.3 .3268 17.06 .6719 4%4
.... 0320 67 .... 1015 38 5.16 .203t 1%4 Bi 8.33 .3281 21/64 ... 17.46 .6875 1¼6
.... 0330 66 2.6 .1024 .... 2040 6 8.4 .3307 t7.5 .6890
.85 .0335 .... 1040 37 5.2 .2047 .... 3320 Q 17.86 .7031 4%4
.... 0350 65 2.7 .1063 .... 2055 5 8.5 .3346 18.0 .7087
.9 .0354 .... 1065 36 5.25 .2067 8.6 .3386 18.26 .7187 2%2
.... 0360 64 2.75 .1082 5.3 .2086 .... 3390 R 18.5 .7283
.... 0370 63 2.78 .1094 %4 ....... 2090 4 8.7 .3425 18.65 .7344 4%4
.95 .0374 .... 1100 35 5.4 .2126 8.73 .3437 W32 ... 19.0 .7480
.... 0380 82 2.8 .1102 .... 2130 3 8.75 .3445 19.05 .7500 3/4
.... 0390 61 .... 1110 34 5.5 .2165 8.8 .3465 19.45 .7656 49/64
1.0 .0394 .... 1130 33 5.56 .2187 7/32 ... .... 3480 S 19.5 .7677
.... 0400 60 2.9 .1141 5.6 .2205 8.9 .3504 19.84 .7812 2%2
.... 0410 59 .... 1160 32 .... 2210 2 9.0 .3543 20.0 .7874
1.05 .0413 3.0 .1181 5.7 .2244 .... 3580 T 20.24 .7969 51/64
.... 0420 58 .... 1200 31 5.75 .2263 9.1 .3583 20.5 .8071
.... 0430 57 3.1 .1220 .... 2280 1 9.13 3594 23/64 ... 20.64 .8125 1¾6
1.1 .0433 3.18 .1250 1/6 ... 5.8 .2283 9.2 .3622 21.0 .8268
1.15 .0452 3.2 .1260 5.9 .2323 9.25 .3641 21.04 .8218 6~
.... 0465 56 3.25 .1279 .... 2340 A 9.3 .3661 21.43 .8437 2%2
1.19 .0469 ~ . .. .... 1285 30 5.95 .2344 15/~ ... .... 3680 U 21.5 3465
1.2 .0472 3.3 .1299 ,6.0 .2362 9.4 3701 21.83 .8594 65/~
1.25 .0492 3.4 .1338 .2380 B 9.5 .3740 22.0 .8661
1.3 .0512 .... 1360 29 6.1 .2401 9.53 .3750 3/6 ... 22.23 .8750 7/6
.... 0520 55 3.5 .1378 .... 2420 C .... 3770 V 22.5 .8858
1.35 .0513 .... 1405 28 6.2 .2441 9.6 .3780 22.62 .8906 6%4
.... 0550 54 3.57 .1406 %4 ... 6.25 .2460 D 9.7 .3819 23.0 .9055
1.4 .0551 3.6 .1417 6.3 .2480 9.75 .3838 23.02 .9062 2%2
1.45 .0570 .... 1440 27 6.35 .2500 I/4 E 9.8 .3858 23.42 .9219 6%4
1.5 .0591 3.7 .1457 6.4 .2520 .... 3860 W 23.5 .9252
.... 0595 53 .... 1470 26 6.5 .2559 9.9 3839 23.81 .9375 1~6
1.55 .0610 3.75 .1476 .... 2570 F 9.92 3906 2%. ... 24.0 .9449
1.59 .0625 ¼6 ... .... 1495 25 6.6 .2598 10.0 3937 24.21 .9531 61/64
1.6 .0629 3.8 .1496 .... 2610 G .... 3£70 X 24.5 .9646
.... 0635 52 .... 1520 24 6.7 .2638 .... 4040 Y 24.61 .9687 3½2
1.65 .0649 3.9 .1535 6.75 .2657 16/64 ... 10.32 .4062 1%2 ... 25.0 .9843
1.7 .0669 .... 1540 23 6.75 .2657 .... 4130 Z 25.03 .9844 6%4
.... 0670 51 3.97 .1562 %2 ... .... 2660 H 10.5 .4134 25.4 1.0000 1

DR2949-ENG
1-28 Elect/eng
 Symbols
Certain symbolsor combinationsof symbolsmayappearon your Volvo PentaSterndrive or accessory,it is very
importantthat youunderstand
their meaning
or purpose,if anysymbolLs not clearly understood,
seeyourVolvoPenta
Dealer.

"Safety Warning"Symbols
|

,, Be Careful Poisonous
/~" Risk of instructions
,, Follow serious injury ~
Fire Hazard
~
Contents Under Pressure

"Position indicator" Symbols

Shift Positions
NEUTRAL

Raise
0 Lower FORWARD REVERSE

"Condition" Symbols
~4

® Voltmeter
(~ Hour’Meter ® Ammeter Tachometer

]~ Voltmeter Oil Filter @ FuelFilter

~ ~ Water Temperature EmergencyStop Oil Pressure

"instructional" Symbols

~L~Gj G" Usegasoline ~ Read Operator’s Manural

as o line i_~ s present ~/,~.~..~ before operating product ~(~ Oil Fill

1-29
Perodic MainenanceChart
Items marked~ Safety Warningare safety related service points to prevent mechanicalfailures, fire and explosion.
Makesure the safety related service is performedat these points and at the intervals specified.

Every 25 Hours or as Every 50 hours or as

Service Point Recommend
ations
Specified Specified
Rechargebattery if
Checkelectrolyte level specific gravity is below
Battery Tighten connections
monthly 1 260 whencorrected for
temperature.
Tighten loose connections
Electrical System Z~ Checkconnections and
and replace deteriorated
insultation. wiring.
Checkfor corrosion, If damaged,replace with
High Tension Leads deterioration or arcing. specified Volvo Penta
and/or Distributor Cap Bootsmustfit snuglyon Parts. Maintainoriginal
terminals. routing andsupport.
Replacewith specified
Checkfor arcing or cracks Volvo Pentaparts.
Ignition Coil /~
in plastic portionof coil. Maintainoriginal location
and mountaing.
If damaged, replace with
Annually check ceramic specified Volvo Pneta
Spark Plugs Z~ for cracks. Replace,or parts.Maintai n o rig inal
clean and gap. routing and support of
spark plug wires.

General TorqueSpecifications
The following specifications are for nut and screw sizes not having specific torque recommendations.

U~.S. Screw Sizes Ft. rob. Nm Metric ThreadSiz es Ft. lb.

No. 6 ... 1.1-1,6

No. 8 ... 2,2-2,8 M6 6-9 8-12

No. 10 2-3,5 2,7-4,7 M8 14-21 19-28

No. t2 3-4 4,1-5,4 M 10 28 -40 38-54

1/420 5-7 6,8-9-5 M12 50-71 68-96

5/16-18 12-14 16-19 M14 80-114 108-155

3/8-16 20-25 27-34

,7/16-14 32-40 43-54

Safety Related 1-30 Elec~eng

 Section 2
Cranking System

Table of Contents
Cranking System Operation .................................. 2-2
Cranking System Problems ................................... 2-9
Starter Motor
Bench Test ............................................... 2-5
Replacernent ............................................. 2-6
Specifications ........................................... 2-10
Test Procedures .......................................... 2-2
Wiring Diagrams,Cranking Circuit .............................. 2-7

/!k Safety Warnings

Before working on any part of the electrical system, read the section called
Safety at the end of this manual.

The original mounting, support and routing of electrical system parts

conform with U.S. Coast Guardrequirements, it is important to maintain
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 componentsmeet

U.S. Coast Guard regulations for external ignition proof operation and
marine use. Volvo Penta marine componentsare 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.

ElectJ’eng 2-1
 Cranking SystemOperation
Thecranking systemconsists of a 12 volt starter motor, solenoid(s), ignition
switch, neutral start switch, 50 ampcircuit breaker, 20 ampfuse and wiring to
completethe circuit with the battery.

Any remotecontrol box used with Volvo Penta Sterndrives must have a neutral
safety switchwhichpreventsoperationof the starter if the control handreis not
in the neutral position. All VolvoPentaremotecontrols meetthis requirement.

Sterndrive starters employa solenoid and lever to close the battery circuit and
engagethe starter pinion with the flywheel ring gear. Whenthe key switch is
turned to START position, an assist solenoid energizes the starter solenoid
whichcloses the battery circuit and throughleverage engagesthe starter pin-
ion with the flywheel ring gear. Whenthe key switch is reFeased,the solenoids
are de-energized,springs openthe battery circuit, and the over-runningclutch
disengagesthe starter pinion.

Starter Motor Test Procedures

Special Tools Required: Battery Hydrometer, Voltmeter, Ammeter,Tachom=
eter, JumperWire
//~k Donot substitute an automotivetype starter. TheVolvo Pentastarter
motormeetsU.S. CoastGuardregulations for external ignition proof op-
eration andmarineuse. The VolvoPenta starter is specially designednot
to causeignition of fuel vaporsin the bilge or engine compartment. The
use of automotivetype starters can result in fire andexplosion.

Inspection Procedure

Noperiodic lubrication of the starter motoror solenoidis required. Starter mo-

tor action is indicative, to someextent, of the starter motorcondition. A starter
motor which respondsreadily and cranks the engine at normal speedwhenthe
control circuit is closedis usually in goodcondition.

Checkthe starter motor and solenoid switch attaching bolts to makesure these
units are solidly mounted;both the starter and solenoiduse their mountingfor a
groundpath. Inspect and manuallycheck nil wiring connectionsin the starter
motor circuit. Makesure these connections in the starter motor and control
circuits are cleanandtight. It is advisableto test the crankingcircuit to ensure
that excessive resistance does not exist. SeeTest Procedure.

//~ Safety Related

2-2 Elec~eng
Test Procedure With Starter installed

Thevoltage across the starting motor and switch, while cranking the engine,
gives a goodindication of any excessiveresistance.
~/~AN remote control boxes used with Volvo Penta sterndrives must
have a neutral safety switch to prevent operation of the starter if the
shift lever is not in the neutral position. Enginemustbe at normal operat-
ing temperaturewhentest is made.

1. Inspect the battery and cables to makesure that battery has amplecapac-
ity for crankingand ignition. Battery mustbe furly charged.

2. Tocrankthe enginewithoutfiring:

Ensureignition switch is off whendisconnectingprimary wires.

Failure to do so mayresult in sparkingthat can ignite fuel vaporsin the
enginecompartment or bilge, andmayresult in fire or explosion.

® All ModelsExcept7.4GL: Turn off ignition switch, and

disconnectboth 2-wire connectorsat ignition coil.

® 7.4GL:Turn off ignition switch, and disconnectengine

harness14-pin connectorat the ignition module.

[_~ 3. Connectthe voltmeter POSITIVE (+) lead to the motor terminal ~)

the solenoid switch; connect the voltmeter NEGATIVE (--) lead to ground
on starter.

4. Turn the ignition switch "ON," crank engine and take voltmeter reading as
quickly as possible. If starter motor turns engine at normal cranking speed
with voltmeter reading 9 or morevolts, the motor and switch are satisfactory.
If the crankingspeedis belownormaland the voltmeter reading is lower than
9 volts, checkfor defective battery, corrodedbattery terminals, or corroded
solenoid.
DR3199
Do not operate starter motor for morethan 10 secondsat a time
without pausingto allow motor to cool for at least two minutes; otherwise,
overheating and damageto the motor mayresult.

Elecdeng ~ Safety Related 2-3

Solenoid Contacts Test

If the starter motor turns the engine at a low rate of speedand the ®
voltmeter reads messthan 9 volts, test the solenoid switch contacts
as follows:

[~volts,
1. With the voltmeter switch turned to any scale above 12
connect the voltmeter I~EGATIVE(-) lead to the motor
terminal (~ of the solenoid switch and connect the POSiTiVE{+)
lead to the battery terminal ® of the solenoid switch.

2. Turn the ignition switch on and crank the engine. Immediately

turn voltmeter switch to low scale and take reading as quickly as
possible, then turn switch back to higher scale and stop the
motor.

Thevoltmeter will read 1/~0 volt or less if solenoid switch contacts

are satisfactory. If voltmeter reads morethan 1/10 volt, solenoid
switch should be repaired or replaced.

Solenoid AmperageTest

An amperage test of the solenoid switch will determine two

things:

® Current draw of both windings in parallel.

¯ Current draw of hold-in winding alone.

®
[~field
1. Removescrew from solenoid motor terminal © and bend
leads slightly until clear of terminal. Groundmotor
terminal of solenoid with a heavy jumper wire @.

r~carbon
2. Connecta 12 volt battery, a variable resistance ® (such as
pile), and an ammeter® of 100 amperescapacity in
series with the solenoid "’S’" terminal @. Connecta heavy jumper
wire ® from starter to ground post of battery. DR3195

F~
3. Connect a voltmeter (~ between the base of the solenoid
and the small solenoid "’S" terminal.

4. Slowly adjust resistance until voltmeter reads 10 volts and note

ammeterreading. This shows current draw of both windings in
parallel, and should be 47 to 55 amperesat 10 volts, with solenoid
at room temperature.

5. Removethe jumper wire from the solenoid motor terminal and

readjust resistance until voltmeter reads 10 volts, then note
ammeter reading. This shows current draw of hold-in winding
alone and should be 15 to 20 amperesat 10 volts with solenoid at
room temperature.

2-4 ElectJeng
6. If the solenoid windings do not test within the specifications
given, the sblenoid switch assembly should be replaced.

Starter Motor Bench Test

[~ To obtain fu[ll performance data on a starter motor, or to
determine the cause of abnormal operation, the motor should be
removedfrom the engine and submitted to a no-load test with
equipmentdesigned for such tests. In a no-load test the starter
motor is connected in series with a 12 volt battery @and an
ammeter ® capable of reading several hundred amperes. A DR3200
variable resistor (L~ is connected betweenthe ammeterand the
solenoid battery terminal. Attach a voltmeter ~ between the
solenoid BATterminal and motor ground ®. Activate the motor
by attaching a jumper wire @between the solenoid’s BATand S
(starter) terminals. A tachometer or RPMindicator is used
indicate armature RPM.Starter motor specifications will be found
at the end of this section.

Comparethe results of the test with the chart below. This will
indicate what should be looked for whenthe motor is overhauled.

TestF|esuBt Pro,bab|eCause
1. Current draw and no- Normalcondition for starting motor
load speedwithin speci-
fications
,2. Lowfree speedand high Toomuchfriction - nameRy tight, dirty or wornbearings, bent armature
current draw shaft, or loose pole shoe screws allowing armature to drag. Shorted
armature. Checkafter disassembly on growler. Groundedarmature or
fields. Checkfurther after disassembly.
3. Fails to operatewith high Direct groundin terminal or fields. "Frozen"I~)earings. Shouldbe noticed
current draw by turning armature"by hand.
4. Fails to operatewith no Openfield circuit. Checkafter disassembly by inspecting internal connec-
current draw tions and tracing circuit with a ~est lamp.
Openarmaturecoils, inspect for badly burnedbars after disassembly.
Brokenbrush spring, wornbrushesor high insulation betweencommuta-
tor bars thus preventing goodbrush to commutator contact.
5. Low no-load speed and High internaBresistancedueto poor connections,defective leads or dirty
low current draw commutator.(Also, causeslisted under4, above.)
6. High free speedandhigh Shortedfield coils. If shortedfield coils are suspected,replacewith new
current draw coils and checkfor improvedperformance.

2-5
Starter MotorReplacement
Removal

Z~Do not substitute an automotive type starter. The Volvo Penta

starter motormeetsU.S. CoastGuardregulations for external ignition
proof operation and marine use. The Volvo Penta starter is specially
designednot to cause ignition of fuel vaporsin the bilge or engine
compartment,Theuse of automotivetype starters can resuWtin fire and
explosion.

1. Disconnectthe battery groundcable at battery and disconnect air wires

at solenoid terminals to prevent sparks in engine compartment.

~] 2. Cut the strap (~) holding drain hose to solenoid. Removenut

from starter support bracket. Removering gear guard (~) from front
flywheer housing. Take out starter mountingscrewsand removethe starter
assembly.

Installation

1. To reinsta{I, position the starter assemblyon the engine and start the
mounting hardware. 6715

2. Snughardwarewhile holding the starter squarely against its mounting

surface. Tighten the screwsto 30-36 ft. Ibs. (41-49 N,m). Install ring gear
guard and tighten screwsto 5-7 ft. Ibs. (7-9 N=m).

3. Connectwires to soJenoidand apply Black NeopreneDip or equivalent to

terminals to prevent corrosion.

4. Connectbattery groundcable at battery. Attach belihousing drain hose to

solenoidwith a tie strap.

2-6 E[ect/eng
 DRC6710 DRC3522

3.0 GS Models 7.4 EIL Models

4.3 GL & GS Models
5.7 GL & GS Models
CrankingCircuit

Q Black
® Red
® Yellow/Red
(~ Starter Relay
(~)Red/Purple
20 Amp Fuse

ElecUeng 2-7
 ® ®

_.~®-

Fuel Injected Models DRC5396

CrankingCircuit
Black
Red
@ Starter Relay
Red/Purple
20 AmpFuse
Yellow/Red

2-8 Elect/eng
 Cranking System Problems

Starter turns engine slowly. Check:

¯ battery water level and specific gravity
¯ for loose and corroded connection,~;
¯ engine and drive unit for binding
¯ starter armature, brushes, field coils, or bearings

Starter turns intermittently. Check:

¯ starter motor - complete tear-down,
¯ connection at ignition switch
e starter solenoid

Starter doesn’tturn - solenoidclicks. Check:

¯ battery and connections
¯ starter solenoid
¯ engine, transombracket and vertical drive for seizure, or
debris
¯ starter armature, brushes, or field coils

Starter doesn’t turn - solenoiddoesn’tclick. Check:

® remotecontrol in start position, shift into neutral
¯ battery and connections
¯ starter solenoid
¯ key switch and wiring circuit 20 ampfuse
¯ 50/60 ampcircuit breaker

Starter remainsengagedand runs with en!~ine. Check:

¯ shorted ignition switch
e starter motor - complete tear-down
e defective electric fuel pump"Orange" lead diode - 4.3 GL
and GS models only

2-9
Starter MotorSpecifications

Z~Donot substitute automotive parts. Volvo Penta marine components

meetU.S. CoastGuardregulations for external ignition proof operation
and marine use. VomvoPenta marine componentsare specially designed
not to causeignition of fuel vaporsin the bilge or enginecompartment.
Theuse of automotiveparts canresuJt Jn fire and explosion.

Motor Free SpeedAt 11.5 Volts (between3-5 seconds)

Current - 64-95Amps
Speed- 2825-3275RPM

//~
Safety Related 2-10 ElecUeng
 Section 3
ChargingCircuit

Table of Contents

Alternator Service
Assembly ............................................... 3-15
Belt Tension .............................................. 3-5
Disassembly ............................................ 3-10
Internal Diagram ......................................... 3-21
Replacement ............................................. 3-4
Specifications ........................................... 3-22
Testing .................................................. 3-7
Circuit Diagrams ........................................... 3=17
Description ................................................ 3-2
Troubleshooting
Alternator ................................................ 3-6
Chart .................................................... 3-8
Wire Harness Tests ....................................... 3-7
Charging System Problems .................................. 3-20

Safety Warnings

Before working on any part of the electrical system, read the section called
Safety at the end of this manual.

The original mounting, support and routing of electrical system parts

conform with U.S. Coast Guardrequirements, it is important to maintain
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 m;3rine componentsmeet

U..S. Coast Guard regulations for external ignition proof operation and
marine use. Volvo Penta marine componentsare 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.
Description

Stator
[~ There are three independent three-phase windings in the
stator, in which three-phasealternating current is incnuded. There
are two types of stator windings used in the alternator, the
"Delta" - connection ~ and the "Y" - connection ®.

Rotor DRC672~

[~] The rotor core and coiU assemblyincludes; a rotor shaft, two
srip rings, two rotor poles and a coil assembly.The rotor shaft is
supported at each end by bearings. The slip rings, core and coil
assemblyare press fitted to the shaft with a rotor pole enveloping
eachend of the coil. Protected slip-type field windings are bonded
with epoxy resin and anchoredto resist damageby vibration from
sharp acceleration.

The rotor assembly is balanced to provide smooth, efficient

operation throughout normal speed range. The slip rings are
made of copper, and thus rustproof, keeping good electrical
4~5~
contact. The rotor core and coil assemblyturns inside the stator
core and coil assembly with a very narrow air gap between the
two assemblies. This narrow clearance permits maximummag-
netic power.

Rectifier

~] The rectifier with six silicon diodes is located between the

stator and the inside surface of the rear bracket.

Three of the six diodes are positive and are located in an

insulated heat sink. The current induced in the stator coil flows 45438

into the heat sink through the diode and comes from the "B"
terminal Three other negative diodes are located in the negative
heat sink that is grounded=

ReguRator if’
The voltage regulator assemblycontains the voltage regula-
tor, brush holder and the brushes.
\-

45439

45448
3-2 Elect/eng
Alternator Replacement
Removal

To ensureproper operation and to protect the alternator and regulator, the

following steps should be observedduring removaland installation.

~ Do not substitute automotive parts. Volvo Penta marine compo-

nents meet U.S. Coast Guardregulations for external ignition proof
operation and marine use. Volvo Penta marine components are spe-
(:ially designed not to cause ignition of fuel vapors in the bilge or 45376
engine compartment. The use of automotive parts can result in fire
and explosion.

{=~ 1. Disconnect the battery ground cable at battery.

2. Remove tie strap © securing alternator wiring harness. Remove

alternator adjusting bolt @from brace. Loosenpivot bolt and nut (~).

3. Pushalternator towardsengine and removealternator belt.

[7.~ 4. Disconnectall leads from the alternator.

45377
[8~ 5. Remove
alternator pivot bolt and nut (~. Remove
the alternator.

mnstaiiation

["~ 1. Position alternator in bracketand loosely install the pivot bolt arqd
nut ®.

L~ 2. Connect purple lead ® to "S" terminal. Connectred/purple lead

,~ to "EXC"terminal Tighten nuts securely and coat both terminals wilh
Black NeopreneDip.

[~ 3. Connectorangelead (13 to "B" terminal. Connectpurple/white lead

45378
,~ to "P" terminal. -righten nuts securely. Slide rubber boots up lead’s
and cover both terminals.

45379

45380
Elect/eng ~ SMety Related 3-3
 45381 45382 45373

[~ 4. Connect black ground lead (~) to "E" terminal. 4.3GL, GS and

7.4GLmodelsonly: Connectthe electric fuel pumplead (~) to the "L2"
terminal. Coat the groundterminal with Black NeopreneDip.

~]5. Pivot alternator towards the engine and place the belt onto the
pulley’. Attach the alternator braceto the alternator with screwA). Follow
the procedurefor "Alternator Belt Tension"in this section. Correctly tension
the belt and tighten all mountingbolts 3 to 26-30ft. Ibs (35-41 N.m)

~] 6. Securethe wiring harnessto the alternator with a tie strap (~).

DR4933
7. Connectbattery cables.

Alternator Belt Tension

® 3.0 GS Niodels [~

¯ 4.3, 5.7, 7.4, and8.2 - All Models[~

Crankshaft Pul|ey

(~) Circulating PumpPulley

DRC43344

(~ Alternator Pulley

(~) 1/~ in. 1/2 in. (6 -13 ram)Deflection

~] J~] With engine stopped, belt should be tight enoughso that it will
deflect ¼to Y2in. (6-13 ram) whenpressedwith a finger at the point indi-
cated (~. If belt is too tight, excessivebelt and bearingwearcan occur, ff
it’s too loose, slippagecan occur, resulting in belt wear; andpoor circulat-
ing pump,alternator, or powersteering operation. Tension of a newbelt
should be checkedafter 10 hours of service and every 50 hours thereafter.

45374
[~]""~ [-~ Checkalternator belt tension (~) midwaybetweenthe circu-
lating pump
pulley (~) andthe alternator pulley C~).

3-4 Etect/eng
1. Loosenalternal:or mountingbolts and nuts, and pivot alterna-
tor awayfrom engine to increase belt tension.

[~ 2. While maintaining pressure on alternator, retighten top

bolt, bottom bolt and nut. Recheckbelt tension.

The belts used for the alternator, circulating pump, and

power steering pump are heavy-duty. Do NOTreplace with
automotive belts.

Whenadjusting alternator belt, do not overtighten. 3he

alternator maybc~ damaged. 45375

Troubleshootingthe Alternator
Belt Tension

I~ Checkthe alternator belt for correct tension. Alternator belt

tension is 1/4-V2 in. (6-13 mm)give with finger pressure at point
shown.

Alternator Output Test

DRC6748
Before beginning charging system checks, test the alternator
output to verify that a charging problemexists.
[~ 1. Disconnect orange lead (~ from "B" terminal at back of
alternator and connect an ammeter@in series.
[~ 2. Attach a w~ltmeter ®to the "B" terminal ~and an engine
ground.

3. Connect a carbon pile or Stevens LB-85 Load Bank across the

battery.

4. Start and run the engine. The amperageand voltage output

readings should be as follows whenthe carbon pile is adjusted to
obtain maximumoutput:

65 Amp Models

650 RPM- 20 ampsrnin.

1500 RPM- 53 ampsrain.
2000+ RPM- 56 ampsrain.

Regulated Voltage RangeAll Models:14.0 - 14.7 volts

Elect/eng 3-5
The output test results will fall into one of these categories;
overcharging, undercharging or no charge at all.

If battery overchargeis indicated by excessive water use, amme-

ter or voltmeter showingconsistent charge, or alternator output
exceeding 15.0 volts (no load) with engine idling, check purple
"S" lead voltage. Lowvolts, or no volts, will causeovercharging.
If purple "S" lead voltage is okay, voUtageregulator is shorted and
must be replaced.

If battery undercharge(or no charge) is indicated, perform the

following tests in the order shown.

Alternator Wire Harness Tests

For the battery to receive sufficient charging current, and the

alternator to supply the correct amount, three wires must carry
battery voltage; the orange output ("B"} lead, the purple ("S")
sense lead and the red/purple excite ("EXC") lead.

CheckNo. 1: Testing Battery Charging Circuit

1. Slide the protective rubber boot off the "B" terminal.

[~ 2. Connectthe vontmeter positive lead to the orange lead (~,

and negative lead to an engine ground ®. With the key switch off,
the voltmeter should show a reading nearly equal to battery
voltage.

Test ResuUts:

a. Circuit Okay- voltage reading is within a few tenths of

battery voltage. Go on to CheckNo. 2.
b. Excessive Resistance - one or more volts less than
battery voltage (example: 10.2 volts versus 11.8 volts}. [~C6747

c. OpenCircuit - a voltmeter reading of zero.

If circuit is openor resistance is excessive, disconnectorangelead

at alternator. With an ohmmeter,check orange lead circuit be-
tweenaBternator and assist solenoid, then red lead circuit back to
battery. Correct any problems, then conduct aDternator output
test again. If output reading is still not as specified, go on to
following test.

3-6 Elec~eng
 CheckNo. 2: Testingignition Circuit

E~ 1. Connect a voltmeter to the "EXC" Read (~ at back of

alternator and an engine ground ®.

[~ 2. With batte~ry connectedand key switch (~ on, the voltme-

ter reading should be within a few tenths of battery voltage.

Test Resunts:

a. Circuit Okay- voltage reading is within a few tenths of

battery voltage. Go on to CheckNo. 3. DRC6746

b. Excessive Resistance - one or more volts less than

battery voltage (example: 10.2 volts versus 11.8 volts).
c. OpenCircuit - a voltmeter reading of zero.
d. GroundedCircuit - a reading of zero accompaniedby a
blown fuse or circuit breaker each time key switch is
turned on.

Results were conditions "b" or "’c’: disconnect both the purple

and red/purple leads from back of aJternator, then use an ohm-
meter to check wire continuity back to key switch. Correct any
problems, then conduct alternator output test again. DRC6745

!~ Results were condition "d": disconnect both the purple and

red/purple leads from back of affernator and repeat voltage check,
Steps 1 and 2 above. If fuse or circuit breaker no longer blows,
circuit is groundingthrough alternator; replace alternator. Fu=se
or circuit breaker continues to blow, check wiring back to key
switch to find cause. Correct any problems, then conduct alterna-
tor output test again.

ff the tests showtile enginewiring, battery or accessoriesare not

at fault, makeadditional running tests on the alternator, Check
No. 3. DRC6744

CheckNo. 3: Testing Excite/SenseCircuit

1. Unscrewprotective cap on "L2" terminal. Retain cap for reuse.

2. With key switch (~ on, but engine not running, check for
1.0-2.0 volts at the "L2" terminal @.

3. if "L2" terminal voltage is not as specified, replace voltage

regulator.

if alternator still fails to producethe specified voltage/amperage

after installation of a newregulator, the alternator will haveto be
disassembledin order to test internal components.

EJect/eng 3-7
 Alternator TroubleshootingChart

Troubleshooting the charging system may involve any one or more of the componentsin the system;
the alternator (including voltage regulator), the charge indicator lamp, the battery and wiring switch
connecting these componentsinto a circuit.

The following troubleshooting chart categorizes trouble and remedies.

Place of
Trouble Treuble Probable Cause Remedy

Battery Fan Belt Fanbelt slipping Readjust the tension of belt

Under-
Charging Alternator 1. Starer coiJ groundedor Repair or replace stator assembly
disconnected if necessary

2. Rotor coil disconnected Replace

3. Brushand sUip ring insufficient Worn brushes to be renewed,

contact (holders to be cleaned) S[ipring
polished

4. Diode intermittently operated Replace rectifier assembly

5. Puncture of capacitor Replace

Battery 1. Not enoughor bad electrolyte Supply, remeasuring specific

gravity

2. Sulfated plate (short circuit) Change battery

3. Unsufficient contact due to Tightening after cleaning

corroded terminal

3-8 E[ect/eng
 Alternator TroubleshootingChart (Cont.)

Ptaceof
Trouble Trouble Probable Cause Remedy

Battery Wiring Disconnection or insufficient Repair

Under- contact between key-switch and
Charging regulator Exc terminal

Ammeter Fan Belt Loosefan belt Readjust belt tension

Needle
Unstable Key Switch Keyswitch insufficient contact Change key switch

Wiring Connection point loose, almost Tightening, repair

disconnected wires

Abnormal Alternator 1. Inferior bearings Change bearings

Noise from
Alternator 2. Puncture of diode Replace rectifier assembny

3. Stator coil groundedor layer Replace stator assembly

shorted

Charging Wiring B terminal shorted Repair

Circuit
Fuse Alternator 1. Positive side and negative side Replace rectifier assembly
Melted diode shorted

2. Capacitor puncture Change

Regulator Over charge Replace regulator assembly

Battery Battery misconnected Connect properly

Alternator Disassembly
To prevent possible fire and explosion, do not substitute
automotiveparts for this alternator or its internal components.
Theseparts and assemblieshave been specifically designednot
to causeignition of fuel vaporsin the bilge.

Regulator/Brush HeRderRemovan
FT] 1. Removeprotective cap (~ from "L2" terminal. Remove
two flange nuts ® and one screw © securing the regulator cover. 45383
Removecover.
[~ 2. Remove two screws @ securing the regulator/brush
holder assembly. Removeassembly.

[~ 3. Removethe nut holding the capacitor. Removecapacitor,

4, Removethree insulators from the "L2", "’P" and "B"

terminals.
[~ 5. Removethe four thru-bolts securing alternator housing.
45384

45385

45386

45387
¯ /~ Safety Related 3-10 Elect;eng
 Rotor Remova~

[~ 1. Set alternator with pulley side down.Insert a screwdriver

on each side of the housing.Pry from underthe stator using any
two lower slots. Do not pry on coil wires.

2. Removethe stator and rear housing from the rotor

assembly.
~8~ E~ 3. Use a soft jaw vise to hold the rotor armature.
Remove the pulley nut (~, washer(~, pulley @, tall spacer ® and 45389
fan ~ from the rotor shaft.

4. Using a plastic hammer,tap the top of the rotor shaft

’while lifting up on the front housing.Remove
short spacerQ and
front bracket®.

45390

45391

45392

45397
Elect/eng 3-11
Bearing Removal

[~ Remove the three screws ~) and retainer ® from front

housing. Support bracket in a press on the inside machined
surface. Press bearing out from the bracket.

Stator Removal
~] Unsolder the stator leads. Hold the rectifier lead with long
nose pliers to protect rectifier from the heat. Remove
the stator.
45396

Rectifier Removal

Remove the screw securing the rectifier to the back housing.

Remove
rectifier.

Testing Stator

The stator consists of three separate windings terminating in a

delta type connection. It producesalternating current for charging
the battery and operating electrical accessories. The windings 45395
must be checked for grounds and open circuits with an ohm-
meter. Any stators with discolored windings should be replaced.

1. Resistance through the stator is very tow, so set an ohmmeter

on the low ohmscale.

[~ 2. Connect the leads to terminals © and (~ and check for

approximately 0.2 ohmresistance. Repeatthis check using termi-
nals © and (~, then terminals ~ and (~. The resistance values
all three checks mustbe the same.If not, replace the stator.
45393

[-~ 1. Set the ohmmeter on the high ohm scale. Connect the
leads betweenone terminal and the stator frame. The meter must
showno continuity (infinity).

2. Repeat this check with the remaining two terminals. If any

reading shows continuity, the stator is grounded and must be
replaced.

45398

J. ~ ~’:~,~:~.~
.¯

45399
3-12 Elec~’eng
’Testing Rotor Assembly
¯ i:~:
The rotor assembly requires two tests; one for shorts and open
circuits, the other for grounds. Conduct both checks with an
ohmmeter.

Clean slip ring surfaces with a fine crocus cloth and wipe
off dust. This will ensure accurate ohmmeterreadings.

1. Set the ohmmeterto the low scale.

I-~ 2. Touch one ohmmeterlead to each snip ring. The meller

reading should be approximately 4.1 to 4.7 ohms at room
temperature. A lower reading indicates shorted windings. A
higher reading shows excessive resistance. An infinity reading
meansan open ciircuit. Replace the rotor if it doesn’t have the . .;~,~:’
,.

specified resistance.

1. Set the ohmmeterto the high scale.

2. Touchone meter lead to a slip ring and the other to the

rotor body. Theonly acceptablereading is infinity. Anycontinui;ty
454O1
’
reading means the rotor assembly is grounded and must be
replaced.

Testing Rectifier (Diode)

The rectifier contains nine diodes. The rectifier converts stator

alternating currentc into direct current as it leaves the alternator.
Tests must be madewith an ohmmeterto check continuity of all
nine diodes in both directions of polarity. 45449

CheckingPositive Diodes
[_~ 1. Test the positive diode by touching the positive ohmmeter
probe to the terminal of each diode and touching the negative
ohmmeterprobe to the heat sink.

?.. All the diodesshouldindicate continuity. If a diode indicates no

continuity, that diode is open, replace the rectifier assembly.

3. Reversethe probesto checkthe diode in the other direction. All

the diodes should indicate no continuity. If it indicates continuity,
that diode is shorted, replace the rectifier assembly.

3-13
CheckingNegative Diodes
L-~ 1. Test the negative diode by touching the positive ohm-
meter probe to the heat sink and the negative ohmmeterprobe to
the terminal of each diode.

2. All of the diodesshould indicate continuity. If a diode indicates

no continuity, that diode is open, replace the rectifier assembly.

3. Reversethe ohmmeterprobes to check the diode in the other

direction. All of the diodes should indicate no continuity. If diode
indicates continuity, that diode is shorted, replace the rectifier 45451
assembly.

CheckingThe Diode Trio

1. Test the diode by touching the positive ohmmeterprobe to

one end of the diode and the negative ohmmeterprobe to the
opposite side of the diode. Then reverse the probes to check the
diode in the other direction.

2. The meter must showcontinuity only in one direction and a

high resistance reading in the other.
45452

3. Repeatthis test on each of the two remaining diode terminals.

Test results must showa continuity reading in the samedirection
for all three diodes, and a high resistance reading in the opposite
direction. If any diode fails a test, replace the rectifier assembly.

Checking Brush and Brush Holder

E~ 1. Check the exposed brush length (~). Minimum exposed
length should be 0.197 in. (5 ram).

2. The contact between the brush and a holder must be smooth. 45410

The insulation betweenthe holder and bracket should be checked

to makesure there is no electrical conduction.

4. Spring pressure range should be between8.8 - 12.3 oz. (250 g

350 g) whenspring length is 0.512 in. (13 ram). If tension low,
the lowering motion of the spring will be stiff and cause inade-
quacyof contact with the slip ring. If pressure is high, wearfrom
friction increases.

3-14 ELecUeng
 45444 45411 45394

Testing Capacitor
[~ The capacitor is held to the alternator rear cover by a single
screw. Use an appropriate capacitor tester and follow the manu-
facturer’s instructions. Thecapacitor capacity should be 0.5 -+ 0.1
microfarad.

Voltage Regulator

Thereare no volt, ohmor amperage tests for the voltage regulator

becauseit’s a solid-state, transistorized component.If all other
alternator componentstest okay, replace the regulator.

Alternator Assembly
Rectifier andStator Installation
~] 1. Install rectifier into the alternator backhousing. Securethe
rectifier with screw. Tighten securely.

16~ 2. Install stator into the front housing. Solder the three leads 45403
to each diode terminal.

Front Housing Assembly

[7~ 1. Press bearing into front alternator bracket until it seats.
Attach retainer to the inside of the bracket with three screws.
"Tighten securely.

18~ 2. Place roto’r in a soft jaw vise. Install front housing over
rotor shaft. Place the short spacer ® on the shaft.
45404
[9~ 3. Place fan @onto the shaft with blades facing down. Place
tall spacer @on the shaft.

[~] 4. Install pulley ®, washerand pulley nut ® onto the shaft.

Tighten nut to 47 ft. Ibs. (63 N.m).

45405
3-15
 45406 45473

Rotorinstallation

t. Position stator with three screws ~ at the top and the

pivot point ® at the bottom. Align the four thru-bolt holes and
tighten bolts ~) securely.

~-~ 2. Install three insulators on the "L2", "P" and "B" terminals.

3. Install capacitor and secure with nut @. Attach capacitor

wire to "B" terminal ~ and tighten securely. Place nut on "P"
terminal ~ and tighten securely. 45407

Regulator/BrushHolder Installation
~ 1. Inspect seal for wear or damage.Place the seal on the
regulator/brush holder assembly.

2. Push in brushes on the regunator/brush holder assembly

and temporarily lock in place with a pin or wire @inserted
through access hole in the brush holder.

[~ 3. Place regulator/brush holder onto the back alternator

45475
housing. Secure the regulator/brush holder assembly with two
screws ® and tighten securely. Seat the seal around the end of
the housing (~. Attach conducting strap to terminal "L2" Q.

4. Removethe temporary holding pin ® to release the

brushes. Spin the alternator to be sure it movesfreely.

[~ 5. Place cover over regulator/brush holder assembly and

tighten the two flange nuts (~ to 51 in. Ibs. (5,8 N.m) and
screw~ to 30 in. Ibs. (3,4 N.m}.

45476

45477
3-16 Efect/eng
®

°
-+ ~6

@
® ®
-~(])" -~ +~~"--@
~ d._.~O
DRC6742

ChargingCircuit Diagram
3.0 GSNlodels
4.3 GL and GS Models
5.7 GL and GS
(~) Black
(~ Red
(~) Purple/White
(~) Red/Purple
q~) 20 AmpFuse
(~) Purple
0 Carburetor ChokeCoil
(~ Orange

3-17
 -® ®
56

©
DRC6741

ChargingCircuit Diagram
7.4 GL Models
(~)Black
(~ Red
(~) Purple/White
Red/Purple
20 Amp Fuse
Purple
O Carburetor ChokeCoil
(~)Orange
 ®
56

T ®

.® °Oo
DRC6740

ChargingCircuit Diagram

Gi and GSi Models

(~ Black
(~ Red
Orange
~) Red/Purple
(~) 20 Amp Fuse
(~ Purple

r-lect/eng 3-19
 Charging SystemProblerns

Battery. Check:
¯ Proper Cold Cranking Ampsrating
¯ All wiring and connections
¯ Specific gravity
¯ Water, add and recharge
¯ Makeload test

Overcharge. Check:
¯ Regulator
¯ Loose connections
¯ Battery

Undercharge. Check:
¯ Belt tension
¯ Regulator
¯ Tarnishedslip rings
¯ Internal alternator components

No charge. Check:
¯ Alternator ground
¯ Belt tension
¯ 20 ampfuse and 50/60 amp circuit breaker
¯ All wiring and connections
¯ Regulator
¯ Tarnished slip rings
¯ Internal alternator components

ignition Misfire. Check:

¯ Alternator ground

Inoperable Electric Fuel Pump.Check:

¯ 4.3 GL, GS and 7.4 GL models only - voltage at "L2"
terminal
 OP
OB

O L2
-O EXC
-OS

OE

DRC6719

Alternator Internal Diagram

O Regulator
(~) Rotor(field)
® Stator
(~ Rectifier
(~) Diode Trio
(~ Capacitor

ElecUeng 3-21
Specifications

Alternator - 65 Amp

Minimum Engine RPMfor Alternator Output ................................... 400 RPM

Regulated voltage range ................................................. 14.0 - 14.7
Amperage output ............................................................ 65
Regulator ...................................................... nnternal, 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
 Section 4

Trim/Tilt Electrical Circuit

Table of Contents

Sending Unit, Trim

Adjustment ................................................ 4-6
Testing .................................................... 4-6
Specifications ................................................ 4-7
Trim/Tilt
Operation ................................................... 4-2
Motor ...................................................... 4-4
Switch ..................................................... 4-3
Troubleshooting ............................................... 4-6
Trim Limiter ................................................. 4-7
Wiring Diagrams
Relay Control Box, Switch and Motor ........................... 4-8
Trim/Tilt Circuit
3.0GS, 4.3GL, GS, 5.7GL, GS Models ............................ 4-9
7.4 GL Models .............................................. 4-10
4.3Gi, 5.7Gi, and GSi Models .................................. 4-11
7.4 Gi Models ............................................... 4-11
Dual-Propeller Models Only ..................................... 4-12

Safety Warnings
Before working on any part of the electrical system, read the section called
Safety 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 servicing the electrical
system to prevent possible fire and explosion in boat’s engine compartment.

Do not substitute automotive parts. Volvo Penta marine componentsmeet

U.S. Coast Guardregulations for external ignition proof operation and marine
use. Volvo Penta marine componentsare 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.

ElecVeng 4-I
Trim/Tilt Operation
VolvoPentasterndrive modelsare equippedwith powertrim/tilt as standard
equipment.The purposeof the trim/tik systemis to enable the operator to
changethe angle of the sterndrive from the helm. Changingthe angle of the
sterndrive in relation to the boat bottomis called "trimming." Trimmingpro-
vides the following benefits:

® Improvesacceleration onto plane

¯ Maintainsboat on plane at reducedthrottle settings

® Increases fuel economy

¯ Providessmootherand/or drier ride in choppywater

conditions

® Increases top speed

Thetrim/tilt switch is located on the remotecontrol handleor on the boat’s

dashboard.The trim/tilt switch changesthe direction of movement of the
boat’s bow. Thetrim/tilt gaugelocated on the dash showsthe corresponding
bowposition.

Trimming
,~ Safety Warning: The boat trim should be adjusted to provide bal-
anced steering as soonas possible each time you get underway.Some
boat/motor/propeller combinationsmayencounterboat instability and/
or high steering torque, whenoperatedat or near the limits of the "Bow-
Up" or "Bow-Down" positions. Boat stability and steering torque can
also vary due to changingwater conditions, if youexperienceboat in-
stability and/or high steering torque, see your Volvo Penta Dealer to
correct these conditions.

Thepowertrim is normallyusedprior to acceleratingonto plane, after reach-

ing the desired RPMor boat speed, and whenthere is a changein water or
boating condition. Locate passengersand equipmentin the boat so that the
weightis balancedfore and aft, andside to side. Trimmingwill not cancelan
unbalancedload.

To operatethe trim, pushthe switch until the desiredbowposition is reached.

Thetrim maybe operated at any boat speedor at rest. Avoid operating the
trim systemwhenrunning in reverse. Observethe trim/tilt gaugewhich indi=
cates the boat’s bowposition achievedby the trim angle of the vertical drive
unit. "Bow-Up"correspondsto the upper portion of the trim range on the
gaugewhile "Bow-Down" correspondsto the lower portion of the trim range
on the gauge.

Z~ Safety Related 4-2 Elect/eng

]he boat will be properly trimmedwhenthe trim angle provides the best boat
performance for your particular operatingconditions. A trim position that pro-
rides a balancedsteering load is desirable°

Tilting

Thetilting featureof the vertical drive unit is also controlled by the trim/tilt
switch. Whenthe switch Js held in the "Bow-Up"position, the vertical drive
unit tilts up until the switch is releasedor the drive unit reachesthe maximum
tilt position. Thetrim/flit gaugewilt indicate the "Tilt" position whenever the
vertical unit is in the tilt range.

Tilting is normallyusedfor raising the vertical drive unit to obtain clearance

whenbeaching,launchingfrom a trailer, or mooring.When tilting the verticai
drive unit, the boat shouldbe at rest or at idle speedonly.

[~ Do not operate the drive unit out of water even momentarily, water
pumpmay be damagedor engine may overheat.

,~ To avoid possible contact with the propeller, never use the

vertical drive unit as a ladderor as a lift to boardthe boat.
Neverboard at the rear of the boat whenthe engineis
running, evenif the engineis operatingin neutral.

Anymalfunctionof the trim/tilt systemcouldresult in a k~ss

of shockabsorber protection if an underwaterobstruction
is hit. Malfunctioncanalso result in loss of reversethrusl
capability. If malfunctionoccurs, see your VolvoPenta
SERVICE DEALER.

Trim/Tilt Switch
Special Tools Required: 12 Volt Test Light

Inspection Procedure: Checkwiring connections, 50 amptrim/tilt circuit

breaker, 10 ampin-line fuse or 10 ampcircuit breaker on pump,and battery
voltage.

Elect/eng ~ Safety Related 4-3

Test Procedure

Whenswitch is operated, current flows from input terminal

(red/purple} to respective output terminals. To check switch"

1. Probe red/purple terminal with test light for voltage, if test

indicates no input voltage, check 50 ampcircuit breaker, 10 amp
circuit breaker on trim pump,or wiring connections.

2. Whenpressing switch down, probe green/white terminal for

voltage.
DR2490
3. Whenpressing switch up, probe blue/white terminal for volt- O Positive Lead
age. ® Negative Leacl

If test light indicates failure, replacetrim/tiat switch.

Trim/Tilt Motor
Special Tools Required:Test Ammeter,(capacity over 200 amps),
Voltmeter, Torque Wrenchand Continuity Tester

Inspection Procedure: Checkwiring connections, 50 ampcircuit

breaker and battery voltage.

Test Procedure

nf the trim/tilt systemwill not operate, refer to Trim/Tilt System

Troubleshootingchart to isolate the problem.

Trim/Tilt Motor BenchTest

To check motor performance, it should be removedand subjected

to a stall-torque test. A stall-torque test is made
to determineif the
motor has sufficient turning powerto hydraulically raise or lower
the stern drive unit in minimumtime. Dueto the construction of
the motor, a no-load test would be inconclusive evidence of
abnormaloperation. Stall-torque tests (one in eachdirection) will
help determine if the motor needsto be replaced or rebuilt.

1. Remove
the trim/tilt motor. Clampthe motor in a vise.

[~ 2. Connect an ammeter ® capable of reading 200 amps in

series with the B+ terminal of a fully chargedbattery and the blue
motor lead ®. Connect a voltmeter © between the two motor
leads.

3. Attach an inch-pound torque wrench to a suitable adapter

@and attach this to the end of the armature shaft.
~] 4. Momentarily complete the electrical circuit by connecting
the green lead ® to battery ground, and note the reading on the
torque wrench and ammeter. The voltmeter reading should be 12
volts minimumduring this test. Ammetershould read 185 amps
maximum.Stall-torque should not be less than 20.6 inch pounds.

4=4 Elect/eng
[~ 5. To perform a stall-torque test in the opposite rotation,
connect the ammeter(~) in series with the battery B+ terminal
and the green motor lead ®. Momentarily complete the electrical
connection by touching the blue aead ® to battery ground. The
:~tall-torque voltage and amperagemust be the sameas in Step 4.

[~ Do not operate the trim/tilt motor any longer than is

necessary to obtain the readings. Allow the motor to cool for
several minutes betweentests. If stain-torque tests are performed
in rapid succession, excessiveheat will be generated, resulting in
lower than normal torque readings and possible motor damage.
DR3939
6. A low current reading with low torque would indicate high (~)Positive Lead
resistance in the internal connectionsor in the brush contacts. A (~ Negative Lead
high current reading with tow torque would indicate faulty
armatureor field windings. Rebuild or replace the motor if it tests
in either manner.

Trim SendingUnit
"[rest Procedure

Removesender from gimbal ring. Disconnect the sender 3=p, in

connector inside the boat.

1. Attach an ohmmeterbetween the "A" terminal black lead and

the terminal "C" black lead of the sending unit. SRowlyrotate the
,,~ending unit control nut counter clockwise until the ohmmeteris
set at infinity or ()pen line (OL), then slowly rotate control
counter clockwise and ohmmeterwill jump to 0 ohms. Continue
to rotate control nut for a highest ohmmeterreading of 625 - 5
ohms.

2. Attach an ohmmeterbetween the "A" terminal black lead and

the terminal "B" white lead of the sender. Slowly rotate control
nut counter clockwise. Ohmmeter should maintain a steady 625 -+
5 ohms.

3. Attach an ohmmeterbetween the "’C" terminal black lead and

the terminal "B’" white lead of the sender. Slowly rotate tl~e
sending unit control nut counter clockwise until the ohmmeteris
set at infinity or open line (OL), then slowly rotate control nut
counter clockwise and ohmmeter,will jump to a highest ohm-
meter reading of 625 - 5 ohms.Continue to rotate control nut for
a lowest ohmreading of 0.

If sender fails one of the three previous ohmmetertests, replace

the sender.

E [ect/eng 4-5
 Adjustment Procedure

[~ 1. Attach an ohmmeterbetweenthe "A" terminal black lead and the

terminal "C" black lead of the sendingunit. Slowlyturn the sendingunit con-
trol nut until the meterreads 11+1 ohm.

[~ 2. With the pivot housingpushedin towardsthe gimbal housing, install

and engagethe sendingunit control nut into the pivot bolt head.Install two
trim sendermountingscrews(~) finger tight.

[~] 3. With the pivot housing pushedin toward the gimbal housing, check
19766
adjustmentof sendingunit. Rotate sendingunit to obtain a 11 + 1 ohmread-
ing on the meter, then tighten mountingscrewsto a torque of 18-24in. Ibs.
(2,0-2,7 N-m).

Trim/Tilt SystemTroubleshooting
~ DuopropModels Only If the trim sender or electrical leads experi-
ence a shorted or opencondition, the trim gaugeneedle movement will be-
comeerratic. All trim/tilt tests mustbe donewith a knowngoodbattery.

~] 1. Verify battery voltage on red/purple lead terminal © and a good

groundconnectionat black lead terminal (~. 19514

[~3 2. Attach voltmeter negative lead to a goodengineground. Attach volt-

meter positive to red/purple lead terminal (~). A reading of battery voltage
indicates a goodI0 ampin-line fuse or 10 ampcircuit breaker. Novoltage
indicates an openfuse, or the circuit breakeris not reset or is defective. On
modelswith the in-line 10 ampfuse, replace it and retest. On modelswith
the 10 ampcircuit breaker, reset the circuit breakerand test again. Replace
the entire assemblyif circuit breakertests defective.

[~[~] 3. With voltmeter negativelead still attachedto engineground,attach

voltmeter positive lead to green/whitelead terminal (E). Activate the trim-
downswitch. Voltmetershouldindicate battery voltage indicating a goodtrim- 19765A
downrelay. Noor very tow voltage indicates a problemin the circuit to and
from the trim switch. Find and correct the problembefore continuing.

[~] 4. Movethe voltmeter positive lead to the greenlead terminal (~). Acti-
vate the trim-downswkch.Battery voltage indicates a goodtrim-downrelay.
Noor low voltage indicates a bad relay. Replacethe entire assembly.

1~]5. Follow the proceduresin Step 3 and 4 to test the trim-up relay. Con-
nect the voltmeter to blue/white lead terminal (~ and blue lead terminal (~.
Lowor no voltage readingsindicate problemsin the circuit or badrelay. Re-
pair or replace as necessary.

I~ 6. Attach the red voltmeter lead to the red/purple terminal (~). Attach
the black voltmeter lead to the solid greenterminal ~ and then to the solid
blue wire terminal (~) with the trim switchin the off (neutral) position. Voltage
shouldreadwithin onevolt of the battery voltage. If the voltageis nearzero,
the relay is defective and the relay assemblyshould be replaced.

4-6 Elect/eng
"Trim Limiter TroubleshootingChart

SYMPTOM POSSIBLE CAUSE CORRECTIVEACTION

The "Black Box"will not accept Trim limiter wiring harness It is very easyto incorrectly con-
any programmed limits. improperly connected. nect the trim limiter into a closed
loop, bypassingthe trim limiter.
Make sure that the cable from
the trim/tilt switch is connected
to the "black box" harness and
not directly connected to the
trim/tilt pumpharness.

Lowbattery voltage. This will occur if battery voltage

falls below about 10.5 volts, re-
charge the battery.

The trim limiter will not allow Low battery voltage Battery voltage has fallen below
the trim pumpto operate. approximately 9.5 volts, shut-
ting downthe trim limiter. Re-
charge the battery.

The trim gauge needle goes to Defective or misadjusted trim With the drive trimmed in the
the top of the gaugerange and sending unit. downposition into the mechani-
stays. cal stops (you mustuse the over-
ride switch to reach this posi-
tion), check resistance between
the two black wires of the trim
sender. Adjust the trim sender
until 11 ohmsof resistance is
reached.

Specifications ..........

Trim/Tilt Motor

BenchStall Test @12 volts

Amperage ........................... 185 maximum
Torque ......................... 20.6 in. lb. minimum
Circuit Breaker
Open ................. within 20-60 seconds @.80 amps
Outdrive Travel Time .... one up/down cycle @40 sec. max.

Trim Sending Unit

Resistance ........................... 0-625 - 5 ohms

Mounting Screw Torque ........ 18-24in. Ibs. (2,0-2,7 N.m)

Elect/eng 4-7
 ®
®

DR247

Relay Control Box

Switch and Motor Schematic
All Models

® Battery O Black
® Relay Control Box Blue
® Pump Motor Blue/White
(~ Trim/Tilt Switch (~ Red/Purple
(~) 10 AmpCircuit Breaker (~) GreenPCJhite
(~)Red/Purple ~) Green

4-8 Elect,’eng
 @

° Oo
==2=

DRC6443

Trim/Tilt Circuit
3,0 GS Models
4.3 GL and GS Models
5.7 GL and GS Models

Q Bnack (~)White
~) Red Relay
® Black (Ribbed Wire) I~ Green
(~ Red/Purple Blue
(~) 20 Amp Fuse Green/White
(~) Purple ~) Blue/white
O Brown/White Red/white
(~) Trim Sending Unit I~ 10 AmpCircuit Breaker

Elect/eng 4-9
 1106

DRC6444

Trim/Tilt Circuit
7.4 GLNiodels

0 Black (~ White
(~ Red L-~ Relay
(~)Black (Ribbed Wire) Green
(~)Red/Purple Blue
(~ 20 Amp Fuse (!~ Green/White
(~ Purple Blue/White
Q Brown/White Red/White
(~ Trim Sending Unit 10 AmpCircuit Breaker

4=10 EEecueng
 ®
5#

+
° Oo

DRC6445

Trim/Tilt Circuit
4.3Gi Models
5.7Gi and GSi Models
7.4Gi, GSi, and 8.2GSi Models

Q Black White
(~) Red (~) Relay
Q Black (Ribbed Wire) Green
(~)Red/Purple @ Blue
20 Amp Fuse (~ Green/White
(~)Purple (~ Blue/White
O Brown/White (~) Red/White
(~ Trim Sending Unit (~ 10 AmpCircuit Breaker

Elect/eng 4-11
 Trim/Tilt
Wiring Diagram
GM
Duoprop® Models Only

Q Circuit Breaker,Trim/Tilt
Q Circuit Breaker,instrumentHarness
Q Trim/Tilt Relay
@ Fuse
® SendingUnit
® Trim/Tilt Limiter
Q Trim Gauge
® Trim Switch, Remote Control
® Tilt-Up OverrideSwitch

WiRE COLOR LEGEND

BN = Brown
BL = Blue
GN = Green
GR = Grey
LBL = Light Blue
LBN = Light Brown
OR = Orange
P = Pink
PU = Purple
R = Red
SB = (Solid) Baack
T = Tan
VO = Violet
W = White
Y = Yellow

FOR MULTI-COLORED WIRES

Thecablecoloris first color,thetrace

color is secondcolor,
for example:
Y/R = Yellow/Red Trace
 ®
®

t~
z

---u
c

u3

C3

,I

o
0
 Section 5
ignition Circuit
Delco EST and D! Systems

3.0 GS,
4.3 GL, GS, Gi, 5.7 Gi, and
7.4, 8.2 Gi, GSi Models
De/co EST System

Table of Contents

Description = Delco EST Ignition System .......................... 5-2

DistrHbutor
Installation ................................................. 5-5
Removal .................................................... 5-4
Service ..................................................... 5-4
ignition Coil Replacement ....................................... 5-8
ignition System Problems ...................................... 5-14
Setting Initial Timing ........................................... 5-7
Specifications ................................................ 5-15
Troubleshooting ............................................... 5-2
12 Volt Positive (E}+) Test ...................................... 5-2
Ignition Coil Test ............................................. 5-3
Pickup Coil Test ............................................. 5-3
Ignition Module Test .......................................... 5-3
Wiring Diagrams, ignition Circuit ................................. 5-9
3.0GS, 4.3GL, and GS Models .................................. 5-9
4.3Gi, 5.7Gi and GSi Models ................................. 5-10
7.4, 8.2 Gi, GSi Models ...................................... 5-12

Safety Warnings

Before working on any part of the electrical system, read the section called
Safety 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 servicing the electrical
system to prevent possible fire and explosion in boat’s engine compartment.

Do not substitute automotive parts. Volvo Penta marine componentsmeet

U.S. Coast Guard regulations for External ignition proof operation and
marine use. Volvo Penta marine componentsare 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.

Elect/eng 5-1
Description
Volvo Penta usestwo Delco ignition systems;the EST(Electronic SparkTim-
ing) systemfor non-EFIengines, and the DI (Distributor Ignition) system
EFI engines.Both consist of a distributor with an electronic ignition control
moduleand pickup coil, a cap, rotor and remotecoil. Theydo not contain
breaker points, a condenser,or centrifugal advance.

Troubleshooting
The following tests are used to check various componentsof either Delco
system. Thesetests should be conductedas necessaryto solve a particular
problem, and should not be part of a normal tune-up procedure. The follow-
ing equipmentwill be needed:

- Ohmmeter
Voltmeter
- Terminal Adaptors
¯ Timing Light
, Timing Adaptor Volvo Penta P/N 885163-6(some models)
Tachometer
o Volvo PentaTest Propeller - Seethe Propeller section of
the Sterndrive/TransomBracket service manual.

~Alt running tests must be conducted in water with the correct test
propeller to properly load engine. Donot performtests with a flushing adap-
tor.

Ignition Coil:
34932
1. Disconnectthe purple and gray wire connectorat coil.

[~ 2. Connectvoltmeter positive (+) lead to purple wire terminal @in con-

nector and the negative(-) lead to engineground®. Turn on ignition switch,
meter should read a minimumof 8 volts.

Distributor:

1. Attach purple and gray wire connectorto coil. Disconnectpink and brown
wire connectorat distributor.

~] 2. Connectvoltmeter positive (+) lead to pink wire terminal © in con- 37708

nector and the negative (-) lead to engine ground.Turn on ignition switch,
meter should read a minimumof 8 volts.

Theignition coil can be checkedfor opencircuits and shorts with an ohmme-

ter. If the ignition coil fails anyoneof the following checksreplaceit. Remove
both wire connectorsfrom coil before performingtests.

DR3302
5-2 Elecueng
 1. To check for short to ground, connect ohmmeterto the
frame @and purple wire terminal (~. With the ohmmeterset on
the high scale, reading should be infinite (oo). A reading of other
than infinity (oo) indicates a short to ground.
[~ 2. To check for an open or shorted primary circuit, connect
ohmmeterto purple wire terminal (~) and gray wire terminal
With the ohmmeter set on the low scale, reading should be .35-.45
ohms. A reading of more than .45 ohmsindicates a possible open
circuit. A reading of less than .35 ohmsindicates a shortedcircuit.
[~ 3. To check for an open or shorted secondarycircuit, connect
DR3302
ohmmeterto purple wire terminal (~) and high tension terminal
@. With the ohmmeterset on the high scale, reading should be
7500-9000 ohms. A reading higher than 9000 ohmsindicates a
possible opencircuit. A reading lower than 7500 ohmsindicates a
shortedcircuit.

Thepickup coil can be checkedfor an opencircuit and shorts with

an ohmmeter.If the pickup coil fails either one of the following
checksreplace it.
@
DR3302

1. Removethe flame arrestor cover (4.3 GL and GSModels Only).

Removescrews securing distributor cap. Removecap and rotor.

2. Release locking tab ® and unplug pickup coil connector.

3. To check for a short to ground, connect ohmmeterto the

body of distributor and either terminal O or @. With the ohm-
meter set on the high scale, reading should be infinite (co).
readingof less than infinity (oo) indicates a shortedcircuit.
[~ 4. To check for an open or shorted coil, connect ohmmeterto
terminals ~ and @. With the ohmmeterset on the high scale, a 34935

good coil should have a constant value between 700 and 900
ohms. A reading higher than 900 ohmsindicates a possible open
circuit. A reading lower than 700 ohmsindicated a shorted circuit.

The distributor’s ignition modulehas only two failure modes,"No

spark" and "No spark advance". After all other checks have been
madeand these conditions still exist, replace ignition module.

34936

34937
Elecdeng 5-3
Distributor Removal
1. Disconnecthigh tension leads from distributor cap.

E~ 2. Lift locking tabs @and unplug both connectorsfrom the distributor.

Crankengineso number1 cylinder is in firing position.

3. Remove two attaching screwsand distributor cap. Noterotor tip position,

and place a referencemarkat this point on distributor housingso rotor/dis-
tributor housingcanbe realigned during installation.
34939
E~ 4. Makea mark ® on distributor base and engine, so the distributor
canbe replacedin its original position duringinstallation.

~lf engine is cranked while distributor is out, completeignition timing

proceduremust be followed. SeeDistributor Installation and Initial Tim-
ing procedure.

5. Remove
distributor clampand lift distributor from engine. Discardgasket.

Distributor Service
~Do not substitute automotive parts. Volvo Penta marine compo=
2"2817
nents meet U.S. Coast Guard regulations for external ignition proof
operation and marine use. Volvo Penta marine components are spe-
cially designed not to cause ignition of fuel vapors in the bilge or en=
gine compartment. The use of automotive parts can result in fire and
explosion.

Remove
distributor from engine (if necessary)following previous procedure.

Ignition Pickup Coil:

2281
1. Pull off rotor.

[~ 2. Place a markon the gear © and the drive tang (g) so that the gear
can be re-installed in its original location. Drive pin from gear and remove
shaft assembly.

E~ 3. Detach leads from module. Pry off retainer (~, and removepickup
coil (~.

Safety Related 5-4 Elect/eng

Ignition Module:

[3 Detach leads and remove the mounting screws @. Removemodule.

Modulemaybe stuck to housingand require prying off.

ignition Module:

i. Clean old Heat Sink Compond

or Silicone Greasefrom mountingsurfaces
of moduleanddistributor.
22818
I~ 2. Apply Heat Sink Compound,
or Silicone Greaseto mounting surface
of module.

[~ Heat sink compoundor silicone grease is necessary for proper heat

dissipation. Failure to use Heat Sink Compound
or Silicone Greasecould
result in heat damageto the ignition module.

3. Position moduleon mountingarea of distributor and install the two mount-

iqg screws.Tighten securely.

Ignition PickupCoil:

1. Align tab and hole (~) and attach pickup coil to pole piece as shown.
Reattachpickup coil leads to module.

~2. Install retainer with Iocking tabs securely positioned in shaft groove
(3.
Shaft, Gear and Rotor:

[-~ 1. Install shaft into housingand assemblegear on shaft. Align gear ©

with tang mark@and secure with roll pin.

2. Align rotor with notch in shaft and press on securely. 23054

%
Distributor installation
Engine Not Disturbed

[ N o---0-~ Usethis procedure

if the rotor/housing/blockrelationship wasmarked,
andthe crankshafthas not beenrotated. If ignition/valve timing relationship
has beendisrupted or engine has beencrankedwith distributor out, install
distributor following Timing Out of Synchprocedure.

1. Position rotor about one-eighthturn counter-clockwisefrom the rotor "ef-

erence markpreviously placed on the distributor housing. 23053
2. Place a newdistributor gasket on engine block Align reference mark on
distributor housing with markon engine Pushdistributor downinto block
until the housingis in a normalinstalled position.

~lt maybe necessary to moverotor slightly to engagedistributor with

camshaft gear and oil pumpdr[veshaft, but rotor/housing/block reference
marksshould properly align whendistributor is downin place.

3. Reinstall hold-downclamp and screw. Tighten screw enoughso you can

just turn the distributor. Attachthe connector(s)to the distributor.

Z~4. Install distributor cap. Tighten screwssecurely to maintain exter-

naJ ignition proof characteristics. Lubricate socketsin the distributor cap
with Marine EP/WheelBearing Greaseor equivalent and install spark prug
wires if there were removed.

5. Timeignition as required. SeeSetting mnitiaJ Timing procedure.

Timing Out of Synch

~Use this procedure if the rotor/housing/block relationship was not

marked,or if the crankshaft has beenrotated and the ignition timing is com-
pletelyoff.

1. Movenumber1 piston to firing position (both valves for number1 cylinder

are completely closed) and align harmonicbalancer timing markwith timing
grid. Number
1 cylinder is nowin position to fire.

[~ 2. Install distributor into engine.After distributor seats, rotor mustbe in

position to fire number1 cylinder as shown.

If distributor doesnot seat in engineblock, press downlightly on distributor

housingwhile turning rotor. After distributor engagesoil pumpshaft, install
distributor clamp and bolt, leaving bolt just loose enoughto permit move-
mentof distributor with heavyhandpressure.
34928

3. Placecap on distributor housing.Rotate housingleft or right until rotor

lines up with terminal for number1 spark plug wire.

4. Checkall high tension wiring, and connect spark plugs wires to cap in
proper sequenceif they have been removed.

5. Attach connector(s) to distributor. Continueon to Setting Initial Timing

procedure.

Safety Related 5-6 Elect/eng

~To prevent a possible explosion, operate the blower as commendled
by the boat manufacturerbefore starting engine. If the boat is not
equippedwith bilge blower, openenginecover or hatch prior to starting
andaeaveopenuntil after engineis running.

Setting initial Timing

[’3 The timing markis stampedon the rim of the harmonict~ balancer. ]he
timing grid is a scale attachedto the timing chain cover. It showsTop Dead
()enter (marked"0") and degreesof advance(before) or retard (after).
eivision on the scale represents 2 degrees. 5159

Preparation

1. Connecta 1 2-volt timing light to number1 spark plug lead, and use :he
timing light following the manufacturer’sinstructions.

~ DANGER! Be careful not to puncture the wire or boot as this would

causea high voltage leak. Makesure that spark plug wires are pushedall ~he
waydowninto the distributor cap terminals and onto the spark plugs. Nipples
must be firmly pushedover the terminals, and boots over the spark plugs.
Failure to do so can result in ignition of fuel vapors in enginecompart=
mentor bilge, andmayresult in fire or explosion. 34929

2. Start engine and leave running until thoroughly warmedup.

~Have someoneat controls. Keep hands, hair and clothing away

from rotating parts while making adjustmentswhenengine is running.

3. Adjust idle speed(non-EFI models)to specified in-gear RPM,then shift

into NEUTRAL. Shut off engine.

Setting Timing

fhe timing procedurefor Delco ESTand DI systemsrequires shunting (shut-

37005A
ting off) the electronic spark advance.Follow the steps that apply to your
specific model.

[=~ Non-EFIModels: Install adapter plug, Volvo Penta 885163-6,into dis-

tributor and connectbare lead to a 12-volt engine B+source. Start engine.

EFI Models: - Start engine and manually set idle speedto 1000 RPM,then
do one of the following:

¯ At the 10-wayDLC(Data Link Connector), starboard front of en-

gine, install a Trouble CodeTool @and turn it on - OR
35948
If a CodeTool is not available, use a jumperwire and connectthe
white / black wire ® to the black wire @inside the connector.

E=oot~ L~ Safety Related 5-7

 34930 34931 25545

All Models °-®

1. Direct beam of timing light onto timing grid. Loosendistributor clamp,then
turn distributor slowly by handuntil timing markis set at the appropriatetim-
ing figure.

2. Rechecktiming mark; reset if necessary.Tighten crampbolt.

3. Stop engine. Non-EFI Models: remove adaptor plug. EFI Models: re-
movethe jumper lead or the Trouble CodeTool.
25551

ignition Coil Replacement

1. Remove ignition coil high tension lead (~), two pin connector(purple
and gray wires) (~, and two pin connector (pink and brown wires) @
theignition coil.

2. Removetwo screws (E) securing coil to engine block and remove

ignition coil.

r~ ,~ 3. Place coil in a vise. wear eye protection. Removetwo rivet

heads(~). Drive the rivets out of the coil. Savethe bracket pieces(~.
34942
[~ 4. Assemblethe two bracket pieces (~) and the coil using two screws
and nuts @provided in the replacementignition coil kit. Tighten screwsse-
curely.

~] 5. Mountthe coil assemblyto the engine block. Secure with two bolts.
Tighten to 20-25ft. Ibs. (27-34N-m).

6. Attach two pin connector (pink and brown wires) © to the coir
shown.Attach two pin connector(purple and gray wires) (~) to the coir
shown.

IT] 7. Apply Marine EP/WheelBearing Grease to the high tension lead 34943
terminalandattachit to the ignition coil.

/~ Safety Related 34944

5-8 Elect/eng
 __J-

/ ®
®
®

DR5052

ignition Circuit
3.0 GS Models
4.3 GL and GS Models

® Black
(~) Red
® 50 AmpCircuit Breaker
(~) Red/Purple
® 20 Amp Fuse
(~) Purple
0 Gray
® High Tension Lead
® Spark Plug Lead
(~ Spark Plug
[~ Tachometer
(~ Pink
(~) Brown
[~ Inductor

ElectYeng 5-9
 Ignition Circuit
4.3 Gi Models
5.7 Gi and GSi Models

O Red
(~ BRack
(~) Red/ Purple
(~ 20 AmpFuse
(~ Purple
(~ Grey
@) Tachometer
(~ EJectronic Control Module
(~ Ignition / Injector Renay
Pink / White
Ignition Coin
Pink
Brown
Black / Tan
[~ White / Tan
Grey / Black
I~ White
Knock Module
Knock Sensor
Black / Green
[~ Brown / Orange
(~ Inductor
~] Splice

5-1 0 ElectYeng
 @
®
®
®

® ®
®
@ ®
® ®
® @
I’
®
®

©1
®
@

E[ectJeng 5-11
 ignition Circuit
7.4Gi,GSi and 8.2GSi Models

(~) Red
(~ Black
® Red / Purple
(~ 20 Amp Fuse
® Purple
Grey
O Tachometer
(~)Electronic Control Module
(~ Ignition / Injector Relay
{~ Pink / White
{~ ignition Coil
Pink
Brown
Black / Tan
White / Tan
{~ Grey / Black
{~ White
Knock Module
Knock Sensor
Black / Green
{~ Brown / Orange
{~} Grey / White
{~ White / Blue
{~ Inductor
{~) Splice
 ®
®
®
® 8
®
®
m

\
®
®

Etect/eng 5-1 3
 Ignition SystemProblems

Engineruns sluggish, overheats. Check:

¯ timing
¯ for proper fuel
¯ compression and for carbon buildup

Enginepings. Check:
¯ timing
® for proper fuel
® compression and for carbon buildup
¯ spark plugs for proper heat range

Enginestarts hard. Check:

® for spark
® spark plugs
¯ compression
¯ battery
¯ distributor cap

Engine misfires. Check:

¯ spark plugs and leads
® rotor and distributor cap
¯ coil
¯ engine firing order and plug wire routing
® engine timing

Enginecranks but doesn’t start. Check:

¯ for spark
¯ coil primary and secondarycircuit wiring
¯ tachometer and wiring
® primary circuit wiring to ignition coil
¯ primary circuit wiring to distributor
¯ ignition pickup coil
¯ ignition modube
Specifications ___

Total Spark Advance

6OORPM ...................................... °10

1000 RPM ...................................... °15
1500 RPM ...................................... °17
2000 RPM ...................................... 19°
2500 RPM ...................................... °20
3000 RPM ...................................... °
21
3500 RPM ...................................... °
22
4000 RPM ...................................... °
22
4600 RPM ..................................... °23

86 AK! Fuel Engine RPN! 89 AKI Fuel

°6 600 °11
°10 1000 °15
°12 1500 °17
°14 2000 °19
°
15 2500 °
20
°
16 3000 °
21
°
17 3500 °
22
°17 4000 °22
°18 4600 °23

Elect/eng 5-1 5
Specifications

EngineFiring Order

j3.0 GS ..................................................
4.3 GL, GS, Gi ........................................
5.7 / 7.4 / 8.2 GL, G{, GSi ............................
1-3-4-2
1-6-5-4-3-2
1-8-4-3-6-5-7-2

ignition Coil = All Models

ignition Coil
Operting Amperage@ 75°F .......................... 1.0 Maximum
Primary Resistance @75°F ........................... 0.35 - 0.45_Q
Secondary Resistance @75°F ....................... 7500 - 9000.Q
PickupCoim
Resistance @75°F .................................. 700 - 900~

Coil must sustain 25-30 kv for 30 seconds

Timing Confirmation Checkpoint

4.3, 7.4, 8.2Gi, and GSi ........................ 17° + 1 ° @1600 RPM

5.7Gi and GSi ................................ 19° _+ 1° @1600 RPM

o
~AII timing figures are -+ 1 without shunt or jumper lead attached.

To test the ignition module, Kent-MooreModuleTester P/N J24642or

equivalentis required. If a moduletester is used, follow the tester
manufacturer’sdirections exactly.

5-16 E[ectJeng
 Section 6

Ignition Circuit
Prestolite Integral BiD System

5.TGL and GS Models

Table of Contents

Distributor
Initial Timing ................................................ 6-9
Installation .................................................. 6-7
Removal .................................................... 6-5
Service ..................................................... 6-6
ignition Coil ................................................. 6-5
ignition System
Operation ................................................... 6-2
Problems .................................................. 6-13
Specifications ................................................ 6-15
Troubleshooting .............................................. 6=10
Wiring Diagram .............................................. 6-14

Z~ Safety Warnings
Before working on any part of the electrical system, read the section called
Safety at the end of this manual.

The original mounting, support and routing of electrical system parts

conform with UoS. Coast Guard requirements. It is important to maintain
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 componentsmeet

U.S. CoastGuardregulations for external ignition proof operation and marine
use. Volvo Penta marine componentsare 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.

Elect/eng 6-1
Presto~ire ignition SystemOperation
©
To clarify operating principles as welt as to simplify the processof
tracing troubles, it should be understoodthat the ignition system
contains two separate circuits.

I~The primary circuit carries the low voltage current supplied by

the battery or alternator. In addition to these sources of
electrical energy, the primary circuit contains the ignition switch
(~, primary winding ~) of the ignition cola, electronic control
module and sensor © located in the distributor, and all low DR4017

tension wiring.

I~duced
rhe secondary circuit carries the high voltage surges pro-
by the ignition coil which results in high voltage spark
betweenthe electrodes of the spark plug in the engine cylinders.
This circuit contains the secondarywinding @of the coil, coil to
distributor high tension lead, distributor rotor and cap ~), high
tension ignition leads and spark pUugs.

[’~] electronics
The electronic ignition system is "integrated", in that the
are housedinside the distributor. Only two con-
nections are madeto the ignition coil. The electronic control DR4016
modulecontained in the distributor is connected to the battery
via the ignition coil positive terminal, and groundedthrough the
distributor base.

[~Acondenser
sensor (E) and trigger wheel ~) replace the points
in the distributor, and control the precise timing
neededto fire the spark plugs. The electronic module® controls
timing and ignition coil saturation by accurateny making and
breaking the ignition coil primary circuit.

[~This ignition system is knownas a "tuned" system. It uses an

oscillator as its sensor. Acting as a "metal detector", it senses 252OO
the trigger wheel teeth turning with the distributor shaft. ]’he
presence of meta~(each tooth} causes a change to occur in the
oscillator which in turn commands the control unit transistor
switch to turn off.

[~This "off" condition causesthe primary current to stop flow-

ing. The magnetic field, which built up during the "on" time,
will collapse across the secondary coil winding causing a high
voltage to fire the spark plug.

DR3563

DR3564
8-2 ElecUeng
 25630 25629

[~] The sensor (~ is a coil of very fine wire moldedinto a plastic

housing. This plastic housing is mountedon the base plate and
connecteddirectly to the circuit board. Thesensor is serviced as
an assemblywith the electronic control module.

[~ The electronic control moduleis a completely self-contained

solid state device which is encapsulated with potting compound
to provide a vibration and moisture proof barrier. It is not
repairable and, if necessary, must be replaced as a complete
assembly.
25628
[~] The distributor is of a conventional design using a centrifu-
gal advance mechanismto control timing.
[~] The ignition coil used with this system has a low resistance
primary winding. A low resistance primary winding achieves
high output for starting. A resistor wire is not used as primary
current is regulated in the electronics.
[~ As mentioned before, this system operates as a metal
detecting system. The detected metal is each tooth of the trigger
wheelwhenit is in close proximity to the sensor coil. Thesystem
is not speedsensitive, that is, it is not necessaryto "generate"an DR3565
electric current by turning the distributor shaft, andwill operateat
any speed above zero RPM.
[~ Whena tooth of the trigger wheel is near the sensor, metal is
detected~), the oscillator is at a low level (~), the transistor is
(~, and no primary current flows. This condition can be compared
to "points open" ~.
[~ Whenthe trigger wheel is awayfrom the sensor, metaa is not
detected®, the oscillator is at a high level (~, the transistor is on
~, and current flows in the primary winding. This condition can
be comparedto "points closed" (~.
DR3566

DR3567
The high voltage surge producedin the secondarywinding of the
ignition coil travers through the cable to the center of the
distributor cap, through the rotor to the adjacent distributor cap
segmentfrom which it is conducted to the proper spark plug by
the high tension ignition wires. The high voatage surge jumps the
gap between the insulated center electrode and the grounded
side electrode of the spark plug, producing the spark required to
ignite the fuel-air charge in the selected combustionchamberof
the engine.

The sequenceof action described aboveis repeated as each tooth

of the trigger wheel movespast the sensor coil, and causes the
transistor to be turned on and off.

The timing of the spark with respect to the piston position in the
cylinder must vary in accordancewith operating conditions if best
engine performance is to be obtained. The spark advance for
obtaining satisfactory idling should be as low as possible. At high
speed, the spark must occur earlier in the compressionstroke in
order to give the fuel-air mixture ampletime to ignite, burn and
deliver its power to the piston as it starts downon the power
stroke.

Control of spark timing to satisfy these constantly changing

operating requirements is obtained in two ways, as follows:

Initial manuaa setting of distributor is madeso that a tooth of the

trigger wheelpassesthe sensor coil at a specified position of the
piston, as indicated by the timing mark on the crankshaft pulley.

I~ Centrifugal advance is governed by engine speed. The

centrifugal advance mechanismconsists of an advance cam, a
pair of advance weights ®, two springs (~ and a weight base
plate.

At idle speedsthe springs hold the advanceweights so that there

is no spark advance, and the spark occurs in accordancewith the 25192

initial manualsetting of the distributor.

As speed increases, centrifugal force causes the advanceweights

to throw outward and push against the advancecam. This rotates
the weight plate causing the teeth of the trigger wheel to pass by
the sensor coil earlier in the compressionstroke, so that the
timing is advanced.

6-4 Etect/eng
Ignition CoiB
Special Tools Required: Ignition Tester

Mostignition coils that are replaced are classified as weak.Many

coils rejected as weakactually test up to specifications and give
normal performance.

A coil that actually is weakwill first affect engine performance

when the ignition reserve is at a minimum. This may be in
starting, tow speed acceleration or top speed. Eventually, the
enginewill fail to start° 22310

High resistance connections in either the primary or secondary

circuit wiring will react the sameas a weakcoil. Widespark pl:ug
gaps, which require higher voltage than the coil can produce, will
put the coil under suspicion. High compressionand lean carbure-
tion increase the voltage requirements, and lead to manyneed-
less coil changes. Leakage of high tension current through
moisture on an unprotected coil terminal may produce carbon
tracks which weakenthe coil output voltage. For this reason, the
nipple on the coil high tension terminal mustbe properly installed
and in good condition.

Whenan ignition coil is suspectedof being defective it should be

tested on a reliable coil tester accordingto instructions suppbied
with the instrument, before being replaced.

Distributor Removal
1. Disconnectthe, distributor primary wires at the ignition coil.
Disconnect high tension leads from distributor cap. Remove
distributor cap=

2. Crank engine so number1 cylinder is in firing position. Note

rotor tip position, and place a reference mark at this point on
distributor housing so rotor/distributor housing can be realigned
during installation.

3. Place a mark on the distributor base and engine, so that 1:he

distributor can be replacedin its original position during installa-
tion.

if engine is cranked while distributor is out, complete

ignition timing procedure must be folRowed. See Distributor
installation and htitial Timing procedure.
4. Remove
distributor clampand lift distributor from engine. Discardgasket.

DistributorService
ADo not substitute automotive parts. Volvo Penta marine compo-
nents meet U.S. Coast Guardregulations for external ignition proof
operation and marine use. Volvo Penta marine componentsare spe-
cially designednot to causeignition of fuel vaporsin the bilge or en-
gine compartment.The use of automotiveparts can result in fire and
explosion.

Disassemblyand inspection

[-N--0~ Major components

can be serviced without removingthe distributor
from the engine.

1. Remove the cap from the distributor. Someengines mayrequire several

high tension leads be removedto allow the cap to be movedout of the way.
Mark the leads and terminals they were removedfrom so they can be re-
peacedin the correct firing order.

2. Wipeout distributor cap with clean cloth and inspect it for chips, cracks
and carbonizedpaths which would allow high tension leakage. Suchdefects
require replacementof the cap. Cleanloose corrosion from surfaces of ter-
minal segmentsinside the cap. Do not use emerycloth or sandpaper.If seg-
mentsare deeply grooved, cap should be replaced. Pull cables from terminal
sockets and inspect sockets for corrosion. Cleansockets using a stiff wire
brush to loosen corrosion. Lubricate sockets with Marine ExtremePressure
(EP) Greaseor equivalent before reassemMyof high tension leads. Check
carbon contact for excessive wear.

[~]3. Removethe rotor andinspect it. If rotor is crackedor rotor tip is badly
burned, rotor must be replaced.

[~] 4. Loosenthe sensor screw (~). Removetwo screws and lock washers 2514,0
(~), then lift out the sensor/ignition moduleassembly.Remove the purple and
black wires from the ignition coil if this assembly
is to be replaced.

[~5. Inspect trigger wheelfor signs of contact with sensor. Checkdistribu-

tor shaft for excessivewear betweenthe shaft and bushingsin housing.

[~ 6. Inspect for excessive wear betweencentrifugal weights and advance

camor pivot pins. Turn advanceplate until weightsare fully extended,then
release and allow weights to return. Repeatseveral times. Springs should
return weights to stop without sticking, and there should be no excessfree
play.
25200

25192
//~ Safety Related 6-6 Elec~eng
Z~7. Distributor housing:Sparksuppression
screensmustbe tightly
in place.

Reassembly

1. ApplyHeatSink Compound
or Silicone Greaseto the bottomedgeof lhe
sensor/ignitionmodule.
E2==~
2. Install sensor/ignitionmodule
assembly
into the distributor housing
andsecurewith two screwsandlock washers(id.
E2=-’13. Rotatethe engineuntil oneof the trigger wheelteethlines upwith 1he 25146

markon the sensor.

E~]4. Adjustthe sensorair gapby sliding the sensorin or out until an.008
in. (0,203 mm)measurement can be taken between the sensorandthe trig-
ger wheeltooth. Tightenthe sensormountingscrew@securely.

E’~5. Install the rotor making sureto align the notchin the distributor shaft
with the rotor. Pushthe rotor downuntil it seats.

6. Attachthe purpledistributorleadto the positive(+) terminalof the ignit

coil. Attachthe blackdistributorleadto the negative
(-) terminalof theignit
coil. Coatthe terminalswith BlackNeoprene Dip or equivalent.

7. Reinstallthe distributor cap.Tightenscrewssecurelyto maintainexternal

ignition proof characteristics.Replaceanyhightensionleadsthat werere-
moved. Paycloseattention to high tensionleadrouting andfiring order.

8, Checkignition timing as required. SeeFinish Timingprocedure.

Distributor Installation
If the distributor hasnot beenremoved
andthe enginewilt run, continueon
to the Initial Timingprocedure.

EngineNot Disturbed
E~Usethis procedure if the rotor/housing/blockrelationship wasmarked,
andthe crankshafthasnot beenrotated. If ignition/valve timingrelationship
hasbeendisruptedor enginehasbeencrankedwith distributor out, install
distributor following TimingOutof Synch procedure.

Elect/eng ~ Safety Related 6-7

1. Position rotor about one-eighth turn clockwise from the rotor reference
markpreviously placed on the distributor housing.

2. Place a newdistributor gasket on engine block. Align reference markon

distributor housing with markon engine. Pushdistributor downinto block
until the housingis in a normalinstalled position.

Notel It maybe necessaryto moverotor slightly to meshdistributor gear with

camshaftgear, but rotor/housing/block reference marksshould properly align
whendistributor is downin place.

3. Reinstall hold-downdampand screw. Tighten screw enoughso you can

just turn the distributor. Connectpurpleprimarywire to coil positive terminal
and black primary wire to coil negative terminal. Coat terminals with Black
NeopreneDip or equivalent.

4. Install distributor cap. Tighten screwssecurely to maintainexternal igni-

tion proof characteristics. Lubricatesocketsin the distributor capwith Marine
EP/WheelBearing greaseor equivalent and install spark plug wires if there
were removed.

5. Timeignition as required. SeeInitial Timingprocedure.

Timing Out of Synch

~Use this procedure if the rotor/housing/block relationship was not

marked,or if the crankshaft has beenrotated and the ignition timing is com-
pletelyoff.

1. Movenumber1 piston to firing position (both valves for number1 cylinder

are completely closed) and align harmonicbalancer timing mark with timing
grid. Number
1 cylinder is nowin position to fire.

2. Install distributor in engine.After distributor seats, rotor mustbe in position

to fire number1 cylinder.

If distributor doesnot seat in engineblock, press downlightty on distributor

housingwhile turning rotor. After distributor engagesoil pumpshaft, install
distributor clampand bolt, leaving bolt just loose enoughto permit move-
mentof distributor with heavy handpressu ret

3. Place cap on distributor housing.Rotate housingleft or right until rotor

lines up with terminal for number1 spark plug wire.

4. Checkall high tension wiring, and connect spark plugs wires to cap in
proper sequenceif they have been removed.

/~ Safety Related
6-8 Elect/eng
5. Connect black primary wire to coil negative (-) terminal.
Connectpurple primary wire to coil positive (+) terminal. Conl:in-
ue on to initial Timing procedure.
Z~ To prevent at possible explosion, operate the blower as
recommended by the boat manufacturerbefore starting engine.
if the boat is not equippedwith bilge blower, openenginecover
or hatch prior to starting and leave openuntil after engine is
running.

Initial Timing 5160

[~] [~ The timing mark is is stamped on the rim of the

harmonic balancer. The timing grid is a scale attached to Lhe
timing chain cover. Bt shows Top DeadCenter (marked "0") and
degreesof advance(before) or retard (after). Eachdivision on
scale represents 2 degrees.

1. Connecta 12-volt timing light to number1 spark plug lead, and

use the timing light following the manufacturer’s instructions;.

Be careful not to puncture the wire or boot as this would

cause a high voltage leak. Makesure that spark plug wires are
pushedall the way downinto the distributor cap terminals and
onto the spark plugs. Nipples must be firmly pushed over the
terminals, and boots over the spark plugs. Failure to do so ~-an
result in ignition of fuel vaporsin enginecompartment or bilge,
andmayresult in fire or explosion.

2. Start engine and leave running until thoroughly warmedup

and choke valve is wide open.

Z~ Have someoneat controls. Keep hands, hair and clothing

away from rotating parts whUemaking adjustments whenen-
gine is running.

3. Adjust idle speed to specified in-gear RPM,then shift into

NEUTRAL.

4. Direct beamof timing light onto timing grid. Loosendistributor

clamp, then turn distributor slowly by handuntil timing mart< is
aligned with the correct degreeon the timing grid. See Specifiica-
tions - Timing and Fuel Requirements.

Elect/eng ~ Safety Related 6-9

5. Rechecktiming mark; reset if necessary. Tighten champbolt.
Recheckidle speed and mixture adjustments.

Prestolite Integral BiD ignition Troubleshooting

Dueto design and operating characteristics of this ignition

system, a high voltage discharge in the coil secondarycircuit may
occur when the ignition switch is turned "ON" and "OFF". The
engine does not need to be cranked for this to occur. Always
groundthe coil high tension lead any time it is disconnectedfrom
the distributor. Failure to do so mayresult in fire andexplosionif
gas vaporsare present.
[~ ignition systems sometimes develop more than one prob-
lem. Be sure to complete the entire troubleshooting procedure
before returning the boat to service.

1. Checksimple things first. Inspect the following and correct any

problems found before preceding.

@ Checkthe coil tower for carbon tracking. Checkprimary

wires for tight connections and proper polarity. Make
sure the tower is clean and dry. Check coil nipple for
proper sealing and insulating qualities, if flash over
occurs here, the enginewill not start.
e Check the distributor cap for carbon tracking and dirt
inside and outside. Moisture and dirt makea good path
for flash over. It is very important that the cap be clean.
Once a track has started, the cap must be replaced.
Checkthe rotor for the samecondition.

@ Checkall high tension leads for proper resistance; 3,000-

7,000 ohmsper foot of lead length. Also check for poor
insulation, burning, cracking and deterioration of the
lead, and torn or cracked plug and distributor cap boots.

® Checkspark plugs for fouling, proper gap and cracked

insulators. Wipeinsulators clean before installing boots.

Z~ 2. Checkfor spark from the ignition coil to the distributor, and

from the distributor to the spark plug using a kilovolt meter.
Follow the meter manufacturer’s instructions when performing
the tests. Do not allow open sparks to occur. Opensparks can
ignite fuel and air vaporsthat maybe presentin the bilge area
and causea fire or explosion.

3. If no spark occurred, removethe distributor cap and rotor, and

align a trigger wheel tooth with the center of the sensor. Check
sensor air gap, which should be .008 in (0,203 ram). Note that the
sensor will operate from a very small gap to a large gap. If the gap
is incorrect, reset to .008 in. (0,203 mm)and repeat the spark test.
Be sure the distributor shaft turns and is not broken or bent.

Z~ Safety Related 6-10 Elec#eng

 DR5066 DR5067

PrimaryCircuit Voltage Tests If voltage is 4 to 8 volts, groundthe high tension

tower of the coil. Place a screwdriver in front of
Position the trigger wheet so that the the sensor face, This will discharge the coil. The
sensor is between two teeth. Turn on the key voltage should nowread 12 to 13 volts. If not,
switch. Primary current should flow. either the coil or the sensor/circuit board assem-
bly is faulty. Test the coil andreplaceif defective.
EEl 1o Connect a vontmeter across the battery Repeattl~e screwdriver test, If no spark, replace
terminals ~®. The meter should read between the sensor/circuit board assembly and reset the
12 and 13 volts. Recharge the battery if the sensor air gap.
voltage is low.
If voltage is lower than 4 volts, removethe wire
EEl EEl 2. Connect the voltmeter between the from the negative terminal (~) of the coil Recon-
negative battery terminal (~ or engine ground nect the voltmeter to the negative terminal.
and the coil positive terminal ©. The reading
should be within one volt of the battery voltage ¯ 12-13 volts - sensor/circuit board assem-
in the previous stop. Performa voltage drop test bly is shorted. Replaceassembly.
if the voltage is morethan one volt low. ¯ 0-4 volts - possible open coil primary
circuit. Replacecoil.
EEl EEl 3. Connect the voltmeter between the
negative battery terminal (~) or engine ground If voltage is higher than 8 volts, checkfor an open
and the coil negative terminal @. The reading distributor groundcircuit or shorted coiJ primary
should be between4 and 8 volts. circuit.
¯ Distributor ground bad - repair.
¯ Distributor groundis good - replace sen-
sor/circuit board assembly.
¯ Shorted coil primary circuit - replace
coil.
 DR5066 DR5067

Voltage Drop Test [~ E~ 2. Connect the positive voltmeter lead

to the sensor/circuit board assemblycase ~, and
Position the trigger wheel so that the the negative voltmeter lead to the negative bat-
sensor is between two teeth. Turn on the key tery post (~). The voltmeter reading should
switch. Primary current should flow. less than one volt. If the reading is higher than
one volt, tighten the system ground connections
[~ [~] 1. Connect the positive voltmeter lead and inspect the battery ground cable. Checkthat
to the positive battery post (~), and the negative the sensor/circuit board assembly mounting
voltmeter lead to the coil positive terminal @. screws are secure. Repeat the test. Replace the
The meter should read less than one volt. Check battery ground cable if necessary.
for poor connections at all attachment points. A
fluctuation indicates a poor connection and re- 3. Check the distributor advance mechanism
pairs must be made before proceeding. Poor along with basic ignition timing. Be sure to
connectionscause heat and get worse, until there operate the engine at the correct idle speedto be
is no current flow. sure of an accurate basic timing adjustment.

6-12 Eiec~eng
 mgnition System Problems

Engineruns sluggish, overheats. Check:

¯ timing and automatic spark advance
¯ for proper fuel
¯ compression and for carbon buildup

Enginepings. Check:
¯ timing and automatic spark advance
¯ for proper fuel
¯ spark plugs for proper heat range
¯ compression and for carbon buildup

Enginestarts hard. Check:

¯ for spark
e spark plugs
® compression
o bypasscircuit
e battery
o distributor cap

Engine misfires. Check:

e spark plugs and leads
¯ rotor and distributor cap
o coil
¯ for loose connectionsat coil and ignition switch
¯ engine firing order and plug wire =’outing
¯ engine timing

Enginefires whencranked, stops whenkey is released. Check:

¯ wiring circuit
¯ ignition switch and connections

Enginecranksbut doesn’t start. Check:

® for spark
e coil and wiring
¯ bypassto coil positive (+) terminal
¯ engine timing and plug wire routing
® tach and wiring
 ®

® ® ®

DR5051
Ignition Circuit
5.7 GL and GS Models
O Battery Purple
® Black ignition Coil
® Red Distributor
® 50 AmpCircuit Breaker Tachometer
® Assist Solenoid (~ Gray
® Red/Purple High Tension Lead
(~ Main Cable Connector [~ Spark Plug Lead
(~)20 Amp Fuse ~Z) Spark Plug
® Ignition Switch Connector
~
TachometerAmplifier

~Optional Equipment
Specifications

Total ignition Spark Advance

86 AK! Fuel Engine RPM 89 AKI Fuel

°
3 600 °8
°
7 1200 °12
°11 1600 °16
°14 2000 °19
°18 2400 °23
°22 2800 °27
°25 3200 °30
°26 3600 °
31
°26 4000 °
31
°
26 4800 °
31

ignition Coil

Operating Amperage @ 75° F .............. 1.0 Maximum

Primary Resistance, in Ohms@75° F .......... 1.26 - 1.54
Secondary Resistance, in Ohms@75° F ........ 9400 - 1100

Coil must sustain 25-30 kv for 30 seconds

Distributor

Sensor Air Gap ................... 0.008 in. (0,203 mm)

 Notes
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 Section 7
Volvo Penta E.E.M. System
7.4GL
Tabteof Contents

Coil or ModuleReplacement................................... 7-21

Distributor .................................................. 7-22
mgnition SystemOperation ...................................... 7-5
Knock Sensor Replacement................................... 7-20
Volvo Penta E.E.M. System
Components............................................... 7-3
Description ................................................ 7-2
OTCIgnition Tester Operation .................................. 7-6
Spark AdvanceCurves ........................................ 7-27
Spark Plug Leads ....................................... Section 1
Specifications ............................................... 7-27
Tachometer............................................. Section 1
Timing Ring Replacement............................ Engine Manual
Timing Sensor Replacement.................................... 7-24
Troubleshooting E.E.M. System................................. 7-11
Crankshaft SensorCircuit Tests ............................... 7-13
Cruising SpeedSpark AdvanceTest ........................... 7-20
Disabled Knock SensorTest .................................. 7-18
Ignition SystemSpark Test ................................... 7-12
KnockSensorCircuit Test .................................... 7-18
S.L.O. IN. SYSTEM- RunningTests ............................. 7-17
S.L.O.W. SYSTEM- Static Tests ............................... 7-16
TachometerCircuit Tests ..................................... 7-15
Wiring Diagrams
Ignition Circuit ............................................. 7-25
S.LO. IN. SYSTEM Circuit ..................................... 7-26

Safety Warnings

Beforeworkingon anypart of the electrical system,read the section called

Safety at the endof this manual.

The original mounting, support and routing of electrical systemparts

conformwith U.S. Coast Guardrequirements. It is important to maintain
the original mounting,support and routing after servicing the electrical
systemto preventpossible fire andexplosionin boat’s enginecompartment.

Do not substitute automotiveparts. VoUvoPenta marine components meet

U.S. CoastGuardregulationsfor external ignition proof operationandmarine
use. Volvo Penta marine componentsare specially designednot to cause
ignition of fuel vapors in the bilge or engine compartment.The use of
automotiveparts can result in fire and explosion.
 Volvo Penta Electronic Engine Engine Knock Sensor
Management System(E.E.M.) A sensor mountedin the cylinder head continually moni-
Description tors for engineknock (detonation or preignition). Should
knockoccur, enginespark advancegradually retards until
Volvo Penta’s Engine Management Systemis an electri- the knockis eliminated. Theenginewill maintain this re-
cal systemthat offers automatic monitoring and mainte- tarded spark advanceuntil engine speedis altered, up or
nanceof variouscircuits. It incorporatesthe following fea- down, by 50 RPMor more. Once a 50 RPMchange oc-
tures: curs, the spark advancewill slowly increase to the appro-
priate spark curve for the present modeof operation. This
S.L,O, W. SYSTEM
(Speed Limiting Operational feature is also programmed to compensatefor changesin
Warning) boat load, weather and altitude. The knock sensor must
groundthrough its mountingthreads in order to operate
Engine sensors continually monitor oil pressure and wa- properly.
ter temperature.If low oil pressureor high water tempera-
ture occurs, the S.L.O.W.SYSTEMwill prevent engine dam- TachometerCircuit
age by signaling an audible warning(if engineis equipped
with a warning horn), and will gradually reduce engine This feature provides an output voltage compatible with
speed by 200 RPMper seconduntil it reaches 2800 RPM. all marine tachometerswhich detect a 12Vto 0V drop for
Low oil pressure or overheating, below 2800 RPM,will their tachometersignaL.Theignition circuit will not be dis-
activate the audiblewarningsystem,but the S.L.O. I/V. SYS- abled if the tachometercircuit is accidentally grounded.
TEMwill not be activated. Lowoil pressure or overheat-
ing, above2800RPM,wilt activate both the audible warn- VariabRe Spark Advance
ing and S.L.O.W. SYSTEM.A 5 second delay is pro-
grammed into the E.E.M. systemcircuitry above 2800RPM There are two spark advancecurves programmed into the
to allow for momentary low oil pressuredue to normal en- ignition module:a normaloperation 89 AKI curve that uses
gine operating conditions. Activation of the S.L.O.W.SYS- the knock sensor to protect the engine and modify the 89
TEMlimits normal engine operation to a maximum of 2800 curve for lower octane fuels (down to 86 AKI minimum),
RPM.If the engine is shut off, the S.L.O.W.SYSTEMwill and an 86AKI"default" curve that protects the enginefrom
reset and allow normal RPMoperation until it activates damageif the knock sensor becomesdisabled. The mini-
again. The S.L.O.W. SYSTEM continues to operate in this mumoctane requirement is 86 AKI fuel, while maximum
manneruntil the causeof low oil pressure/high water tem- performance is obtained with 89 AKI or higher octanefuel.
perature is corrected.

~Upon engine start-up, the audible warning device

will sounddueto lack of engineoil pressure.This is a nor-
mal operating condition.

Engine SpeedLimiter

This feature prevents engine damagethat can be caused

by excessive RPM.If engine speed exceeds the upper
limit of its programmed operating range by 200 RPMor
more,the RPM limit circuit will activate andceaseignition
firing. Thecircuit continuesto operateas long as an over
speed condition exists. Onceengine speed drops back
into the programmed range, the RPM limit feature will de-
activate and allow normaFoperation

7-2 Elect/eng
Cruising Spark Advance

Whenthe engine is operated at a stable speed between2200-3400RPM,

additional ignition advancewill be addedto the 89 AKI curve to improvefuel
economy.If knock is detected whencruising advanceis added, the cruising
advancewill be modified (retarded) enoughto stop knock. If the knock sen-
sor is disabled, cruising advance
will not function. This feature will not func-
tion whenengine RPMis outside this range.

Ignition System

20039
This is a breakerlesselectronic ignition systemthat fires one cylinder at a
time. Noadjustmentis required, and maintenance is limited to periodic dis-
tributor cap and rotor replacement.

Volvo Penta E.E.M. SystemComponents

[~] Timing Ring

The timing ring mountson the crankshaft betweenthe flywheel and en~oine
coupler. Timing rings with 4 outer vanes are used on 8 cylinder engir,es.
Eachouter vane tells the E.EM.modulewhento fire a cylinder. The inner
ring is a "start-up" referencefor cylinder #1.

[~ Timing Sensor

The timing sensor is mountedon the upper port side of the bell housing
underneatha protective cover. It’s easily replaceable without removingthe
bell housing.It’s an electronic switching device that receives its powerand
ground from the E.E.M. module. TwoHall Effect switches inside the sensor
are activated by movementof the timing ring, sendingelectrical impulsesto
the moduleto operate the ignition system.

Coil Module 28262A

The coil moduleis mounteddirectly on top of the E.E.M. moduleon the in-
side of the port high-rise exhaustelbow. Thecoil modulecontains one 12 volt
coil having a minimumof 25-30 KVoutput.

E.E.M. Module

-]he E.E.M. module(~ is located beneaththe coil module. It sends and re-
ceives electrical impulses by meansof a 14-pin connector. It monitors ;~nd
controls all Volvo PentaE.E.M.functions as noted in Description. Themod-
ule must be groundedto operate. E.E.M. modulesare not interchangeabEe;
they have specific fidng orders, RPMranges and spark advancecurves.
Theyare stampedwith a part numberand the liter displacementfor identifi-
cation.

Elect/eng 7-3
E~ Distributor

The distributor directs the high tension voltage from the coil to the
correct spark plug. The distributor is unconventional in design as it
doesn’t have any spark advance mechanism. Spark advance and tim-
ing are controlled by the E.E.M. module. The only componentsrequir-
ing periodic maintenanceare the rotor and distributor cap.

[~ Engine Knock Sensor

28183A
The knocksensor is located at the rear of one cylinder head. It can sense
knockfrom any cylinder, and sendssignals to the E.E.M. moduleso timing
can be altered to prevent engine damage.Theknock sensor must be grounded
in order to operate,ff the knocksensoris disabled, the enginewill default to
the 86 AKI spark curve.

[~ Oil Pressure Switch

Anoil pressureswitch (~) is installed in a "T" connectorwith the oil pressure

gaugesender. When the switch closes, the optional audible alarm will sound,
and S.L.O.W.SYSTEM circuit operation will be triggered if engine speedis
at least 2800 RPM. 22242

[~ Water Temperature Switch

The water temperature switch is mountedseparately from the water tem-

perature gaugesender, either at the top or starboard side of the enginewa-
ter pump.Whenthe switch closes, the optional audible alarm will sound,and
S.L.O.W. SYSTEMcircuit operation will be triggered if engine speedis at
least 2800 RPM.

E~] 12.5 AmpCircuit Breaker

30799
This protection device © is located on the enginecable bracket, at the front
of the starboardriser. Thecircuit breakeris in-line between
the ignition switch
circuit and the and the E.E.M. module.

2224

22248
7-4 ElecUeng
Igr|ition System
Operation
Whenthe key switch is turned on, battery voltage passes through a 12.5
ampcircuit breaker, then through a 14-pin connector to the E.EM.module.
Twowires connect the moduleto a single 12 volt ignition coil. Themodule
sendsbattery voltageto the coil positive (+) terminal, andelectronically opens
and closes the coil groundto breakthe primary circuit and fire the coil. The
:Tlodule also connects through a 4-pin connector to a flywheel housing-
mountedtiming sensor.

The sensor assemblyis composed of two Hall Effect switches with a perma-
nent magnetpositioned betweenthem. The sensor works in conjunction with
a timing ring to providethe modulewith cylinder firing signals. Thetiming ring
is a zinc-plated disc having two raised concentric rings, and is mountedbe-
tweenthe flywheel and the engine coupler. The inner ring acts on the inner
(lower) Hall Effect switch, and is solid except for a single "window"(an open
section of the ring). Theouter ring acts on the outer (upper)Hall Effect switch,
and has windowsequal to one-half the numberof enginecylinders (e.g. an
cylinder enginewouldhave4 windows).A solid portion of either ring is calted
~ vane

Themagneticlines of force acting on the Hall Effect switches are controlled

by the windowsand vanes of the timing ring. A windowallows the magnetic
lines of force to act on a Hall Effect switch, and"closes" it or "turns it on". A
vane blocks the magneticlines of force, and "opens" or "turns off" the Hall
Effect switch. Theinner ring windowslightly overlapsone outer ring window.
This "double window"is the key for triggering the E.EM.moduleto fire No. 1
cylinder on start-up. After start-up, all cylindersare fired only by the outerring
windowsand the outer (upper) Hall Effect switch.

Themoduletransmits approximately2 volts less than battery voltage to 1he

timing sensor, and provides a return path through the sameconnector to
groundthe sensor inside the module. The remaining two sensor wires pro-
vide the modulewith cylinder firing signals. Thetwo Hall Effect switchesopen
and close as the windowsand vanes of the timing ring pass betweenthem
and the permanentmagnet.Resistors in the timing sensor circuit inside 1he
moduledrop the returning voltage downto approximately5 volts. As a win-
dowappearsand a t-lall Effect switch closes, the 5 volts in the returning
sensorwire drops to 0 volts, Whena vane appears, the voltage returns to 5
volts. The"double window"provided for starting causesa double drop (0-0
volts) in both sensorreturn wires, andthe modulelooks for this signal before
initiating sparktiming.
Thetiming ring rotates as the engineis cranking. It alternately passesvanes
and windowsthrough the timing sensor, sendingfluctuating voltage signals
to the module. Whenthe modulereceives the dual drop (0-0 volt) start-up
signal, it fires cylinder number1 within one crankshaft revolution. Thecoil
fires whenthe moduleelectronically opensthe primary circuit on the ground
side of the coil. This collapsesthe electromagneticfield built up by the pri-
marycircuit, and inducesa current into the ignition coil secondarywindings.
This high secondaryvoltage is transmitted througha high tension lead to the
distributor. Therotor then distributes spark to one cylinder at a time in the
proper firing order muchlike a conventionalignition system.Initial engine
timing is programmed into the modu[ealong with the total spark advance
curve.

As the timing ring continuesto rotate, the outer (upper) switch will become
inactive as the next vaneappears.As long as a solid portion of the ring is
betweenthe magnetand Hall Effect switch, the sensor is inactive. Whena
windowappears,the moduleinitiates a timed dwell period, then fires a cylin-
der. As RPMincreases, the windowspass through the sensor at a faster
pace. The modulesenses this increase, and will advancetiming, accord-
ingly.

Spark advance is programmedinto the module and is dependent on the

status of the knock sensor. WhenRPMdecreases, timing is retarded. This
cyclic firing action occurs throughoutthe operating RPMrange, and contin-
uesuntil the ignition switchis shut off.

OTCElectronic ignition Tester, PIN D3200

Operatinginstructions
TheOwatonna Tool Co. Electronic Ignition Tester is designedto provide quick
visual checks of major Volvo Penta E.E.Mcircuits to determine if they’re
functioning properly. It also allows isolation checksof individual circuits by
attaching voltmeters, ohmmetersand tachometers to the Tester. The OTC
Tester is a necessary tool whentroubleshooting performanceproblemsre-
lated to the Volvo Penta E.E.Msystem. Order this instrument from Owatonna
Tools; it is not available from your VolvoPentaDistributor.

~TheOTCIgnition Tester is only capable of checking circuit inputs to

the E.E.M. module. It cannot be used to check the internal function of the
moduleitself. The E.E.M. moduleshould be replaced if the enginecontinues
to malfunctioneventhoughall circuits that connectto the moduleare operat-
ing properly.

7-6 ElecUeng
 \\

"VOi,’~r(~

ELECTRONIC ENGINE
MANAGEMENT SYSTEM

TACHOMETER

(~----
@-- ~/ MODULE POWER

MODULE GROUND

TIMING SENSOR
POWER O ~®i’ A
TIMING SENSOR
GROUND O B
TIMINGSENSOR
SIGNAL @ 0 @ @ ~. C
TIMING SENSOR
START SIGNAL ~O D
CRANKING TEST

WARNING
SWITCH

SHIFTASSISTTEST

KNOCKCONTROL
SYSTEM
TEST KNOCK
SENSOR
TEST
MODULE
TEST

GR960147cdr

Following is a description of each of the Tester circuits, Absenceof LEDlight while cranking or running would in-
and what they indicate whenconnected to a properly func- dicate loss of tach signal from modute.
tioning engine. Remove the 14-pin connector at the
E.E.M. module. Connect the OTCTester in series between Failure Symptom: Tachometer will not function.
the connector and module. The tester will be inactive until
the boat’s ignition switch is turned on.
(~ Module Power
@ Tachometer
LED indicates module is receiving battery power
LED indicates module is providing correct tach
signal If operation is nominal:

If operation is nominal: O Key On - LED will light

o Engine Cranking - LEDwill flicker, then

¯ Key On - LEDindicator will be off remain lit constantly
¯ Engine Cranking - LED will flash ¯ Engine Running - LEDwill be lit con-
¯ Engine Running - LED will flash stantly

Absenceof LED light in any situation would indicate mod-

ule not receiving battery current, or moduleis not grounded.

Failure Symptom: Engine cranks, but will not start. En-

gine quits while running.

7-7
 "V’OL’rAI’O
~LmE,Z~7’r.A.
ELECTRONICENGINE
MANAGEMENTSYSTEM

MODULE POWER 0 , P
MODULEGROUND ’@/ M

TIMING SENSORPOWER 0 o~ A
D,-ITIMING SENSORGROUNDi @ "0 B

TIMING SENSORSIGNAL i
I 0 0 0® 0" C
TIMING
SENSOR [
STARTSIGNAL I ® o D

~"~[ CRANKING
TEST

WARNINGSWITCH

ISHIFT ASSISTTEST o
KNOCK CONTROL
® .2 SYSTEM TEST KNOCKSENSORTEST ’ -IH]
MODULETEST
_ i ’

© Module Ground (~ Timing Sensor Ground

NoLEDIndicators - test point is used to verify module LED indicates correct sensor ground at module
ground as described in Troubleshootingthe VolvoPenta
E.E.M. System. Perform this test if ModulePower LED If operationis nominal:
doesnot light.
¯ KeyOn- LEDwill light
Failure Symptom: Engine cranks, but won’t start. Engine ¯ EngineCranking- LEDwill stay lit
quits whiFerunning. constantly
® EngineRunning- LEDwill stay lit
@ Timing Sensor Power constantly

LEDindicates moduleis supplying voffage to sensor

Absenceof LEDlight indicates modulehas lost sensor
If operationis nominal: ground.

® Key On- LEDwill light FaimureSymptom:Engine cranks, but won’t start. Engine
quits while running.
¯ EngineCranking- LEDwill flicker, then
remainlit constantly
® EngineRunning- LEDwill be lit con-
stantly
Absenceof LEDlight in key on or running situations indi-
cates moduleis not supplying powerto timing sensor.

Failure Symptom: Enginecranks, but will not start. En-

gine quits white running

7-8 EtectJeng
 "VOLVO
X=E~TT.PA
ELECTRONICENGINE
MANAGEMENTSYSTEM

t_J_
le ¯ E1
O op
I MODULEGROUND

TIMING SENSORPOWER

TIMING SENSORGROUND

TIMING SENSORSIGNAL
~~ TIMrNG SENSOR

. STARTSIGNAL

CRANKINGTEST

~"~~ WARNINGSWITCH
_ ® "_’_El
SHIFT ASSISTTEST +
@___~,.
KNOCK CONTROL
SYSTEMTEST KNOCKSENSORTEST

MODULETEST

~F~ Timing Sensor Signal Absenceof flashing LEI~) while cranking or running indi-
cates sensoror sensorwiring failure.
LEDindicates moduleis receiving sensor/timing ring
spark plug firing signal Failure Symptom:Engine cranks, but won’t start. Engine
misfires while running.
If operation is nominah
(~ (;:ranking Test
¯ KeyOn- LED’swill be off
¯ EngineCranking- LED’s flash slowly No LEDindicators - test button is pushedto prevent en-
and sequentially gine starting whenperformingcranking only tests.
¯ EngineRunning- LED’sflash faster or
slower as RPMincreases or decreases (~) Warning Switch Test
Absenceof flashing LED’s while cranking indicates sen- Checks operation of module S.L.O.W. SYSTEM
sor or sensorwire failure. circuit

~.~ Timing SensorStart Signal If operationis nominal:

LEDindicates moduleis receiving sensor/timing ring ¯ Key OnLEDwill light (becauseof oil
start signal pressure switch)
¯ EngineCranking- LEDwill stay lit
if operationis nominal: unlessoil pressureincreasessufficiently
to turn off LED
¯ KeyOn- LEDwill be off
¯ EngineRunning- LEDwill be off, if oil
¯ EngineCranking- LEDwill flash very pressure and water temperature are
slowly normal
¯ Engine Running- LEDflashes faster or
slower as RPMincreases or decreases

7-9
 "VOX.,’~TO
PE][~’T.A.

ELECTRONIC ENGINE
MANAGEMENTSYSTEM
., _

~ TACHOMETER @ i. E

@-..-I MOOU,E
GROONO
TIMING SENSOR
POWER !O oj A
TIMING SENSOR
GROUND ,0 ’0 B
TIMINGSENSORSIGNAL 1®@@O C
TIMINGSENSOR
STARTSIGNAL @ D
CRANKING
TEST .~]

WARNING
SWITCH O" -~~

SHIFTASSISTTEST I @ ~ ~ i 10; G
KNOCKCONTROL KNOCK
SENSOR
TEST
SYSTEM
TEST
MODULE
TEST

WarningSwitchTest Cont. (~ KnockControl System Test

Checksoperationof the warningswitchcontrol Checksoperationof moduleknockcontrol circuit.
circuit andS.L.O.W.circuit operation.
There are no LEDindicators. Tests performed with
® EngineRunning- LEDon indicates a the two test buttonswill require useof a variable ad-
problemin S.L.O.W.SYSTEM circuit, vancetiming light.
either high enginetemperature, low oil
pressureor wiring circuit ground e First Test Button- simulatesloss of
¯ Engine RunningAbove2800 RPMand signal fromknocksensor(e.g. discon-
ButtonPushed- LEDwill go on; button nectedwire, or defectiveknocksensor),
will simulateactivationof a warning andtriggers moduleto default to the
switch, andtrigger EE.M.module Inactive KnockSensorSparkCurve. See
S.L.O.W.SYSTEM circuit operation Troubleshooting the VolvoPenta
after aninitial 5 seconddelay E.E.M.Systemfor test procedure.
FailureSymptom: audible warninghorn will sound(if so ¯ Second Test Button- simulates a
equipped), and if engine speedis above 2800 RPM, knocksignal andtriggers moduleto
S.L.O.W. SYSTEMcircuit will slowlyreduceengineto this retard spark advancein programmed
steps. SeeTroubleshooting the Volvo
RPM.Below2800RPM,only the audible warninghornwill PentaE.E.M. System.
sound(is so equipped),the S.L.O.VV.SYSTEM circuit will
not be activated. Failure Symptom: Enginemayknock(ping) heavily when
engineis underload, dependingon gasolineoctanerat-
ing of the fuel beingused.

7 - 1 0 Elect/eng
Troubleshooting the Volvo Penta E.E.M. System
Followingare diagnostic steps usedto isolate problemsin the various opera-
lional modesof the Volvo Penta Electronic Engine Management System.
Thesetests wouldbe conductedas necessaryto solve a particular problem,
aqd should not be part of a normal tune-up procedure.The following equip-
ment will be needed:

¯ OTCE-lectronic Ignition Tester, P/N D3200

¯ Ohmmeter
¯ Voltmeter
¯ TimingLight with variable timing advancefeature
® Kilovolt Tester
¯ Tachometer
¯ Jumper Leads with Amphenolpins
o Volvo Penta Test Propeller P/N 985007(right-hand rota-
tion), or P/N 985626(left-hand rotation)
hNote PArlrunning tests must be conductedin water with the correct test
propeller to properly load engine. Donot performtests with a flushing adap-
tor.

VolvoPentaE.E.M. Circuits
Timing Sensor
® Tachometer
© S.L.O.W. SYSTEM
Knock Sensor
Ground
(E) 12V to Module
@ Ground
 PENTA
ELECTRONIC
ENGINE
MANAGEMENT
SYSTEM
% PElq’rA
ELECTRONICENGINE
MANAGEMENTSYSTEM

MODULE
GROUND
TA
NOME’ER
] J T--iTII
MODULE
POWER ~
MODULE
3ROUNO

TI~41NG
START
SENSOR
SIGNAL
TIMINGSENSOR

TIMING
SENSOR

STARTSIGNAL

CRANKING
TEST
POWER
TfMINGSENSOR
!
GROUND
!
SIGNAL.
TIMINGSENSOR
I

I
%
! ,.j
O
O

WARMING
SWITCH
1 ’~¢1 F]
I’1
SHIFTASS~ST
TEST ] I--
KNOCKCONTROL
SYSTEM
TEST KNOCK
SENSOR
TEST .Ir j
MODULE
TEST

GR960155 GR960149

Ignition SystemSparkTest 3. Connecta jumper wire betweentest points "M" and "C".
This will disable the sensorcircuit andpreventenginestart-
Z~ Checkfor spark output with a Kilovolt Tester fol- ing. Attach a voltmeter to test point "P" and moduleground
lowing the manufacturer’s instructions. Donot use a de- "M". With KEYON,checkfor battery voltage. If meter shows
battery voltage, crank motor and check for a minimumof
vice or method that produces a spark in the bilge. If no
7.5 volts at test point "P". Themodulerequires a minimum
spark, checkthe spark plugs, spark plug leads, distributor
cap, rotor, high tension lead and coil. Makethe following of 7.5 volts to function.
supplementary tests with the OTCElectronic Ignition
If battery voltage waspresentwith key on, but meterfailed
Tester:
to showa minimumof 7.5 volts while cranking, perform
[~]1. Remove14-pin connector at E.E.M. module, and cranking circuit troubleshooting checks.
connect OTCTester. With KEYOFF, connect an ohmme-
If meter did not showbattery voltage with key on, use a
ter betweentest point "B" and modulemountingstud. Us-
voltmeter to check all componentsand wiring that make
ing high ohmscale, meter must show ZERO(0) ohms.
up the crankingand ignition circuits.
[~ 2. With KEY OFF, connect an ohmmeter between
a. 12.5 AmpCircuit Breaker
test point "M" and modulemounting stud ground. Using
high ohmscale, meter must show ZERO(0) ohms. b. Starter Assist Solenoid
c. 50 AmpMain Wiring Harness Circuit
If modulefails either test (showssomeresistance value), Breaker
checkenginegroundingcircuit. If groundingcircuit is okay, d. Main Wiring Harness Cable Connector
replace E.E.M. module. If modulepasses tests No. 1 and
2, makethe following additional checks: e. 20 AmpIgnition Switch Fuse
f. Ignition Switch
9. Wiring And Connections From Key
Switch To Module
h. Battery Connections

Z~ Safety Related 7-12 ElectJeng

 % volvo
1~ENT-4L
ELECTRONIC ENGINE
~
~.’

MANAG ~ "MEN
T S Y$TEM

TT~OI’IOMETER L__ ,®11"7~i

;SENSORPOWER IoA
SENSOR
GROUND
’T SENSOR
SIGNAL +
I@!+~!
; SENSOR
SrGNAL

~A’qKINGTEST
FA6MNGSWIIC~
~L~ss,sT
TES-[
..... ........... I+l I "IGI J

GR960154 GR960161

CrankshaftSensorCircuit Tests [~] 3. With KEYON,check for 2.5 to 5.0 volts (high)
0.0 to 1.0 volts (low) at test point "C". Slowlybumpengine
Disconnect the 14-pin connector at the E.E.M. module. over (do not crank continuously). Voltageshould alternate
Connectan OTCElectronic Ignition Tester in series be- from high lo low 4 times per revolution on 8 cylinder en-
tween the moduleand 14-pin connector. Before conduct- gines.
ing the following tests, turn KEYONto checkthat test point
"P" LEDindicator is lit, (indicating module
is receivingvolt- E~ 4. Wil:h KEYON,checkfor an identical 2.5 to L5J 5.0
age), and take a voltage reading. Performall tests with volts (high) or 0.0 to 1.0 volts (low) at test point "D". Again
voltmeter connectedbetweenthe appropriate test point slowly bumpengine over. Voltage should be h=ghfor most
and moduleground "M". of one revolution (345°), and should go low only one bme
for a short period (15°).
[-3-~ 1. With KEYON,checkfor voltage at test point "A".
This reading should be approximately2 volts less than a
w)ltage checkmadeat test point "P".

[~3~ 2. With KEYON,check for ZERO(0) to 0.5 volts

at test point "B’.
Crankshaft
Sensor
Circuit Tests [~ 6. Use an ohmmeterset on the high ohm scale and
(Cont.) check for groundedcircuits betweenpins A, B, C, D and
engine ground.
TURN KEYOFF.If engine fails ANYof tests No. 1 thru 4,
removethe OTCElectronic Ignition Tester from the en- If tests No. 1 thru 4 are failed, but tests No. 5 and6 are
gine cable 14-pin connector. Remove 4-pin connectorfrom passed,replace the crankshaft sensor. If either tests No.
sensor on bell housingand perform the following tests: 5 or 6 are failed, replace the wiring harnessthen repeat
tests No. 1 thru 4.
[~ 5. Use an ohmmeter set on the high ohm scale U
and check for continuity betweenpin A of the 14-pin con- ~Check sensor for damage. If sensor probes show
nector, and pin Aof the 4-pin connector. Repeatthese con- signs of contact, sensor mayhave been improperly posi-
tinuity checksbetweenpins B, C, and D of the 14-pin and tioned wheninstalled, or timing ring on crankshaft maybe
4-pin connectors. bent or distorted. Timing ring vanes must be true within
0.015 in. (0,38 mm).

To replace the sensor, refer to Timing Sensor Replace-

mentelsewherein this section. To replacethe timing ring,
refer to the appropriate Enginemanual.

7-14 E[ect,’eng
 "VOLVO
ELECTRONICENGINE
r~ANAGEMENTSYSTEM

I -F-Fq
ITACHOMETER [
r
I MODULE
POWER
!--
P MODULE
GROUND

TIMINGSENSOR
PO~Ri _ ® ,’, A"
TIMINGSENSOR
GROUND
I ®
~IMINGSENSOR
SIGNAL olo o e
TIMINGSENSOR
STARTSIGNAL o ®;! D

GR960153 GR960142

’TachometerCircuit Tests E~ 2. RemoveOTCTester from engine cable U 14-pin

connector and unplug main engine harness. Set an ohm-
!3isconnect the 14-pin connector at the E.E.M. module. meter on tlhe high ohmscale and checkfor continuity be-
Attach an OTCElectronic Ignition Tester in series with the tween pin "E" of the 14-pin engine cable connector, and
14-pin connector and the module. Before performing the receptacle No. 2 of the main harness plug. Makea sec-
following tests, turn KEYONto check that test point "P" ond ohmmetercheck for a groundedcircuit by checking
LEDindicator is lit, indicating moduleis receiving voltage. betweenpin "E" and engine ground.

ET~ 1. Connecta voltmeter betweentest point "E" and If mainwire harnessfails either of the checksin test No. 2,
moduleground "M". With KEYON,check for 3.0-3.5 volts replace the wire harness and repeat test No. 1. tf mare
less than battery voltage (high) and 0.0-1.0 volts (low). wire harnesspassesthe test. performa similar test on the
SFowlybumpthe engine over. Voltage should alternate instrument harness betweenplug No. 2 and the gray ta-
lrom high to low 4 tLmesper revolution for 8 cylinder en- chometerlead. ff the inslrument harnessfalls either tesL
gines. Agrounded tachometer,or groundingof pin "E", will replace the harness.If it passesthe test, replace the ta-
not disable the ignition system. chometer. See Tachometer in the General Information
section.
Goon to test No. 2 only if the moduledelivers fluctuating
voltageat test point "E". If 12 votts are present,but there is
no high-low variation whenengineis bumped over, replace
1he module,if modulepassestest No. 1, problemlies with
lachometeror in wiring from engineto dash.

IElect/eng 7-15
 :PE~T~
ELECTRONIC ENGINE
MANAGEMENT SYSTEM

III II
TACHOMETER ]ei I.o IEI
MODULEPOWER

MODULEGROUND

TIMING SENSORPOWER @
TIMING SENSORGROUND O B
TIMING SENSOR
SIGNAL I®[® @® ° C
TIMING SENSOR l°
STARTSIGNAL I® D
I
CRANKINGTEST
’it
WARNINGSWITCH IOI I "~LFI
i
SHIFT ASSISTTEST
iol.I - I
I
KNOCKCONTROL
SYSTEMTEST KNOCKSENSORTEST "IHI
MODULETEST

F-T-
Volts

GR960152 GR960143

S.L.O.W. SYSTEM
Circuit - Static Tests [~] 2. Set an ohmmeteron the high ohmscale and
checkfor an opencircuit (NOcontinuity) betweenwater
Disconnectthe 14-pin connectorat the E.E.M. module. temperatureswitch terminal andengine block. Replace
Attachan OTCElectronicIgnition Testerin series between switchif metershows continuity. If metershowsan open
the 14-pin connectorandthe module.Before performing circuit (NOcontinuity),an additionalswitchtest is neces-
the followingtests, turn KEYONto checkthat test point sary. Performsenderimmersion test specified in General
"P"LEDindicatoris lit, indicatingmodule
is receivingvolt- Informationsection underOia and WaterSendingUnits.
age. If senderpassesimmersion test, problemlies with gauge
[~1. Disconnectthe wiring harnessat the oil 25 pres- or wiringto dash.
sure switch(blade terminal), the watertemperature switch [] 3. Set an ohmmeteron the high ohmscale & I and
(blade terminal), andat the warninghorn(if so equipped). test for continuitybetween
oil pressureswitchterminaland
Connecta voltmeter betweentest point "F" and module engineblock. Replaceswitchif there is no continuity, if
ground"M". With KEYON,checkfor 0.0-1.0 volts at test switchtests okay, performadditionalswitchtest described
point "F" whenthe oil pressure and water temperature underRunninnTest that follows.
switch leads are groundedone at a time to the engine
block. Goon to tests No. 2 and3 if wire harnesspasses
this test. Replacewireharness if youfail to get the speci-
fied readings.

7-16 ElectJeng
 PEI~T’]E’,#tL
ELEC TRONIC ENGINE
MANAGEMENT SYSTEM

TACHQMFTER

MODULEPOWER

MODULEGROUND

TIMING S,-NSORPOWER ®
QI
TIMING S~-NSORGROUND @
TIMING SENSORSIGNAL
TIMINGS~-NSOR
START
SIGN,~,L I@
CRANKINGTEST
III
WARNINC,
SWITCH .L~

/
SHIFT ASSISTTEST
J
KNOCKCONTROL
SYSTEM[EST KNOCKSENSORTEST

MODULETEST
-Jz

GR960148 GR960151

S°L.O.W. SYSTEM
= RunningTests [~ 3. Run the engine again at 3500 RPMin forward
gear. Usea iumper lead and groundtest point "F" to the
~1. Install the proper test wheel on the drive. Discon-
moduleground"M". This will activate the S.L.O.W. SYS-
nect wire harness lead from oil pressure sender (blade TEMcircuitafter an initial 5 seconddelay.
terminal). With ENGINERUNNING at idle, use an ohm-
meter on the high ohmscale to check for an opencircuit Replacethe moduleif 1he RPMfails to drop as specified.
(NOcontinuity) betweenthe oil pressure switch terminal If in test #3 the engine RPMdrops as specified, the en-
and the enginebloc;l<. If switch passesthis test, and has gine/accessoryharnessshould be tested for opencircuits
passedprevious check descnbedunder Static Test prob- and test #2 repeatedalter repairs.
lemlies with wiring to dash. Attach senderlead after com-
pleting test. ~lf the tan/black wire is shorted to ground at any
point, the S.L.O.W.SYSTEM circuit will activate eachtime
[~] 2. Disconnectthe tan/black lead at the warninghorn. engine speed exceeds 2800 RPMfor more than 5 sec-
Runthe engine at 3500RPMin forward gear, and ground onds, and the optional audible warning horn will sound
the warning horn lead. The engine RPMshould drop to continuously. OnceS.L.O.W. SYSTEM has been activated,
2800RPMat a rate of 200 RPMper secondafter an initial the ignition switchmustbe shut off to reset it.
5 seconddelay. Goon to test No. 3 if enginefails to drop
RPM.

Z~~ If test is performed with engine below 2800

RPM,engine speedwill not drop. Makesure test is per-
formedin gear at the specified RPM
for accurate results.
Tests maybe performed on the water using a propeller;
however,since enginecover maybe removedfor this test,
appropriate safety precautions must be taken to prevent
personal injury as boat speed decreases when the
S.L.O.W. SYSTEM is activated.

~e~t,,’~.g Z~ Safety Related 7-17

KnockSensorCircuit Test
This test will require the use of a timing light with an adjustable advance
feature. A shop tachometer can be connected to test point "E" if an OTC
Electronic Ignition Tester is attached to the E.EM.module.

Z~ WearSafety GRasses.
Install the propertest propelleron the sterndrive.
Takecare to avoid movingbelts and pulleys while engine is running.

Run engine at 3000 RPMin neutral and observe timing mark on balancer
with timing light. Enginetiming should be figure shownin chart below. Re-
peatedly strike block or cylinder headnear knock sensorwith a medium size
steel hammer. Timingwill retard in steps as tong as youcontinueto strike the
engine. Whenstriking stops, timing will stop retarding and remainat a, re-
ducedspark setting. Timingwill retard to a basefigure if knockingcontinues
long enough. The secondknock contror button on the OTCtester simulates
this check. Whenengine RPMis artered up or downby 50 RPMor more,
spark advancewill slowly increase up to the normal 3000RPM setting speci-
fied below.

3000 RPMTiming Figure with Active KnockSensor (89 AKI)

e 31°-+1°
3000 RPMTiming Figure with Inactive KnockSensor (86 AKI)

o 25° -+ 1 °
~Theknock control system is designed with proprietary circuitry which
is self-adjusting for enginebackgroundnoise. As the engine wearsand gets
looser, the knocksensingcapability is not affected. If the knocksensorwire
is shorted to ground, the modulewill stay on the 89 AKI curve, but without
knockprotection.

The moduledetects the presenceof the knock sensor by sensing a complete

groundcircuit in the black/green wire. The modulemonitors a knock sensor
ACvoltage signal that varies in frequency and amplitude dependingon the
severity of the detonation.

Disabled KnockSensor Test

This test wilW require the use of a timing light with an adjustable advance
feature. A shop tachometer can be connectedto test point "E" if an OTC
Electronic Ignition Tester is attachedto the E.E.M.module.

Z~ Safety Renated 7-18 ElecUeng

1. Install the correct test wheelon the drive. Runthe en- If enginefails to respondproperly, replacethe E.E.M.mod-
gine at 3000RPM in neutral, and with a timing light, verify ule. Problemis with knocksensoror wiring if spark retards
that the timing advanceis correct for this RPM.Refer to as specified.
the 3000 RPMTiming Figure With Active KnockSen-
sor chart for the correct timing degrees. Knock sensor can be checked by connecting an AC volt
meter set on the 2 volt scale to engine ground and the
~The engine will stay in the Active Knock Sensor knock sensor terminal. Tap the block near the knocksen-
Spark Curve as long as the knock sensor wire is not sor and checkfor a voltage reading. A voltage reading in-
grounded. dicates a g~oodknocksensor. Noreading, replace the sen-
sor.
[1~] 2. With engine running at 3000 RPM,remove lead
flom knock sensor. ]he spark advanceshould retard to Using an ohmmeteron the high ohmscale, check wire
the figure listed below Disabled KnockSensorTiming continuity betweenpin H of engine cable connector and
Figure. The first knockcontrol button on the OTCtester moldedconnectorat knocksensor. Also checkfor a shorted
simulates this check. If spark advancedoes not retard to to groundcircuit.
the specified figure, reconnectthe knocksensorlead and
performtest No. 3. DisabledKnockSensorTimingFigure - 3000
RPM
3. Disconnectthe 14-pin connectorat the E.E.M. module.
Connectan OTCElectronic Ignition Tester in series be- ~When the knock sensor is disabled by removing
tween the 14-pin connector and the module. Runthe en- wire or pushingfirst knocksensortest button, the E.E.M.
gine at 3000 RPMin neutral and push first knock sensor moduledefaults to inactive KnockSensor Spark Curve,
test button. This will activate the knocksensorcircuit, and and engine power decreasesaccordingly. ReplaceE.E.M.
retard the timing to the figure specified in the Disabled moduleif spark advancedoesnot retard to this figure:
KnockSensorTiming Figure chart.
¯ 25° +1°
KnockSensor Replacement
The knocksensoris a sensitive device and mustbe handledwith care,
If it’s dropped,or is otherwisesharply struck, it should be replaced.Threads
of knocksensor and mountinghole must be free of paint, corrosion or other
material that mayprevent good contact with block. The knock sensor must
groundthrough it mountingthreads in order to function properly. Whenin-
stalling knocksensor, tighten to 7-10 ft. Ibs. (9,5-13,5 Nm). Donot usean
impact wrench,and do not overtighten; knock sensor will be damaged.

Cruising SpeedSparkAdvanceTest
This is a test for the supplementalspark advancethat occurs in the cruising
speedrange from 2200RPM to 3400RPM.This test will require the use of a
timing light with an adjustable advancefeature. A shop tachometercan be
connected to test point "E" if an OTCElectronic Ignition Tester is attachedto
the E.E.M. module.

~Knock Sensor must be active for cruise advance to operate.

1. InstalF the proper test wheel on the drive. Refer to SparkCurveWith

Active KnockSensorat the end of this section and record the 2500 RPM
timing figure. NOTE:Thesespark advancefigures do not have the cruising
speedspark advanceaddedin. Watchthe timing mark with a timing light,
and run the engine up to 2500 RPMin neutral. Recordthe degrees of ad-
vance seen at 2500 RPM.

~ Engine must maintain 2500 RPMfor 3-4 seconds before the advance
will begin. If knocksensorcircuit is disabled(open), enginewill not go into
cruising advance.

2. After a 3-4 seconddelay at this RPM,the spark advancewill gradually

increase to the cruising speedadvance. Whentiming stabilizes, total ad=
vance should be the Active Knock Sensor figure plus the Cruise Advance
figure. Refer to the following chart for the amountof additional(not total)
advance.

Additional Cruising SpeedSpark Advance

°+1°
¯ 10
Whenengine RPMmovesout of the cruising RPMrange, the modulereturns
to normaloperation, and seeksthe best powerspark advancefor the present
fuel, load and operating condition. If the spark timing fails to advanceas
specified, checkfor a disabled(open)knocksensorcircuit. Replacethe E.E.M.
moduleif knocksensorcircuit is okay.

28262A
7-20 Elect/eng
Coil or E.E.M. ModuleReplacement
Removal

["=~ 1. Unscrew14-pin connector (~) at E.E.M. module, and removespark

plug lead from coil. Remove
moduJeand coil assemblyfrom mountingbracket
on high-rise elbow.

[2~] ~ 2. Use a ]25 -rorx screwdriver and removecoil module. Unscrew

bracketsupportingcoil, andlift coif out of cover.
~ 3. Slide grommet® off coil high tension tower. Makecareful note 28204

of lead colors and which terminals they connectto, then disconnect E.E.M
moduleleads from coil. Removeand discard modulegasket ©.

[~ If moduleleads are not attached to the correct coil terminals, polarity

will be reversedand ignition systemwill not function properly.

~1. Checkthe resistance of the ignition coil primary circuit. Set an ohm-
meter on the low ohmscaie, and attach the meter leads to the coil positive
(+) and negative (-) terminals. Properresistance is 1.26-1.54 ohms.
35134
[~ 2. Checkthe resistance of the ignition coil secondarycircuit. Sel an
ohmmeteron the high ohmscale, and attach the meter leads to either coil
primary circuit terminal, and to the terminal inside the high tension tower.
Proper resistance is 9400-11,000ohms.
®
3. If an ignition coil is suspectedof beingdefective, it canbe checkedwilh a
reliable ignition coil tester following the instructions suppliedwith the instru-
ment.

4. Ignition coil condition can also be checkedwith a Kilovolt Tester. Theigni-

tion coil must sustain a secondaryvoltage output of 25-30 kilovolts for at
least 30 seconds.Performthis test following the instructions of the Kilovolt 35132

-Fester manufacturer.

Test Resunts:If the ignition coil fails anyof the precedingthree tests, replace
it.

- o Y’ Y®e -

The E.E.M. moduleis a solid-state componentand cannot be checkedwith

normaltest instruments. Replacethe moduleif it fails the specific tests de-
scribed under Troubleshooting the Volvo Penta E.E.M. System. Modules
are stampedwith a part numberand the liter displacementfor identificat!on.
Donot install the wrongmodule. 28207

~,...

28206
Electleng 7-21
Instsllation
[~ 1. Install a newgasket(~) on module.Attachmoduleblue lead to coil
positive(+) terminal.Attachmodule yellowleadto coil negative(-) terminal.
lead connectionsare not made correctly, coil polarity will be reversedand
ignition systemwill not functionproperly.
[~ 2. Slide grommet ~) onto coil high tension tower. Placecoil in module
cover andmakesure grommetseals cover opening.Position bracket over
coil, then install mounting
screwsandtighten themsecurely.
[~ 3. Position coil moduleon E.E.M.module.Install screwsand tighten 35132

securely.
[~ 4. Install coil andmoduleassemblyonto high-rise elbowbracket. At-
tach14-pinconnectorT to module,andattach hightensionlead to coil.

- e o. ,~1 =-] o yV - "

See Spark Plugs, Leadsand Firing Order in General Information

srction.

Distributor 35134

Removal

~] 1. Remove distributor capandcrank engineso number1 cylinder is in

firing position andreferencemark(~ on distributor shaft gaugeis in align-
mentwith the referencemark(~ on the distributor housing.Makea refer-
encemarkon the intake manifoldin alignmentwith the referencemarkon
the distributor housing.

2. Remove
the distributor clampandlift distributor out of engine.

28204

2~6~

@
DR3821
7-22 ElecUen,
installation ]
[NO--0-~Proper positioning of the distributor rotor relative to the distributor
body(rotor registry) ~s very important to insure correct ignition firing. The
enginemayappearto run satisfactorily even if the rotor position is not set
correctly. But under certain spark advanceand load conditions, the spark
mayarc fromthe rotor tip to the wrongdistributor terminal, andresult in mis-
fire or enginebackfire.

[~ 1. Apply engine oil to the distributor gear and end of shaft, Align the
reference mark(~ on the distributor shaft gaugewith the reference markon
the distributor housing(~. Position the housingreference markin alignment 2818

with the markmadeon the intake manifold or at the 10 o’clock position (as
viewedfrom rear of engine). Install the distributor in the enginewhile m~Jn-
taining alignmentof the distributor gaugeand housingreference marks.

2. With the distributor completelyseated, install hold downclamp.Rotate the

distributor housinguntil alignment markon housingaligns with distributor
shaft gauge, and tighten hold-downclamp screw securely.

[~ E~ 3. Install distributor cap. Tighten the hold-downscrews securely.

Install the ignition high tension leads(~) on the distributor capand route
shown.

~The number 1 spark pUug wire tower should be over the align-
ment marks, if not, recheck procedure and install again.

~4. Start the engine and checkfor proper operation. Water testing is
recommendedto properly load the engine.

Elec~Jeng ~ Safety Related 7-23

Timing Sensor Replacement
RemovaJ

[~ 1. Remove
nuts from sensor cover and lift cover off flywheel housing.

E~ 2. Remove
nuts and washers, and lift sensor off flywheel housing.

3. Releasesensorclip, andpull sensoroff electrical lead.

InstaWlation
19994A
1. Makesure waterproofseal is in place, then pushelectrical lead into sen-
sor until it cNpsinto place.

E~ 2. Place sensor on mountingstuds and press spring tab to allow proper

positioning of sensorover timing ring. While holding spring tab depressed,
install a washerand nut on eachstud, and tighten both nuts to 48-60in. Jbs.
(5-7 N.m). Rechecksensor position after installation by depressingtab
seeif it contactstiming ring. If tab contactsring, loosennuts andreposition
sensor.

If sensoris not properlyinstalled, timing ring will contactsensorwhen

engine is cranked. Sensorwill be damaged and will have to be replaced. 19993A

3. Placecover over sensor.Install two self-locking nuts and tighten to

48-60in. Ibs. (5-7 N.m).

18848

7-24 Elect/eng
@

-
l® *]

DRC6311

VolvoPentaE.E.M. ignition Circuit

~) Battery ~ Spark Plug
(~) Black (~) White
(~) Red (~ Green
(~) 50 AmpCircuit Breaker (~ Purple/Green
(~) Assist Solenoid (~ Black/VVhite
~) Red/Purple (~ Purple/Yellow
Q) Main Cable Connector @ Timing Sensor
~) 20 AmpFuse I~) 2 Pin Connector
(~) Ignition Switch ~ Black/Green
~J Purple I~) Distributor
1(~l 12.5 AmpCircuit Breaker @ Knock Sensor
~} Coil and E.E.M. Module (~ Purple/Black
~) Spark Plug Lead (~ High Tension Lead
 ®

DRC3931

VolvoPentaE.E.M.S.L.O.W.Circuit

Q Battery (~ Coil and E.E.M. Module

® Black (~ Spark Plug Lead
® Red (~) Spark Plug
(~ 50 AmpCircuit Breaker [~ Oil Pressure Switch
O Assist Solenoid (~ Water Temperature Switch
(~) Red/Purple @ Purple/Black
Q Main Cable Connector (~ Tape
(~) 20 AmpFuse [~ Audible Warning Horn
(~) ignition Switch {~) Tan/Black
Purple ~) High Tension Lead
(~ 12.5 AmpCircuit Breaker @Distributor

7-26 EiecUeng
Specifications

Spark AdvanceCurves
inactive KnockSensorSpark Curve(86 AKI)

RPM 7°4 GL

1000 °12
1500 °17
2000 °22
2500 °24
3000 °25
3500 °27
4000 °30
4600 °
34

OptimumSpark Curve With Active KnockSensor (89 AKI)

RPM 7.4 GL

1000 °13
1500 °20
2000 °28
2500 °29
3000 °31
3500 °32
4000 °33
4600 °
36

ignition Coil

Operating Amperage@ 75° F .............. 1.0 Maximum

Primary Resistance, in Ohms@75° F .......... 1.26 - 1.54
Secondary Resistance, in Ohms@75° F ...... 9400 - 11,000

CoiB must sustain 25-30 kv for 30 seconds

Elect/eng 7-27
 Notes
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..........................................................................................
 Section 8

Electrical System

Table of Contents

GM MFI ................................... 8-1

GMTBI .................................. 8-13

GM MFI
Circuit Breakers .............................................. 8-2
Engine Control Module (ECM) ................................... 8-3
Engine Coolant Temperature (ECT) Sensor ....................... 8-4
General Information ........................................... 8-2
Idle Air Control (IAC) Valve ..................................... 8-7
Inductor ..................................................... 8-3
Intake Air Temperature (iAT) Sensor ............................. 8-6
Knock Sensor (KS) ............................................ 8-8
Knock Sensor (KS) Module ..................................... 8-9
Manifold Absolute Pressure (MAP) Sensor ........................ 8-4
Relay OhmmeterTests ........................................ 8-10
Relay Replacement ............................................ 8-3
Thrc~ttle Position (TP) Sensor ................................... 8-5
Torque Specifications ........................................ 8-11

Safety Warnings
Before working on any part of the electrical system, read the section
called Safety at the end of this manual.

The original mounting, support and routing of the electrical system parts
conform with U. S. Coast Guardrequirements. It is important to maintain
the ~riginal mounting, support and routing after servicing the electrical
system to prevent possible fire and explosion in the boat’s engine
compartment.

Do not substitute automotive parts. Volvo Penta marine components

meet U.S. Coast Guardregulations 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.
General Information
The ECMand awl EFI sensors are sensitive eaectronic components.
Observethe following cautions whenservicing them:

o Verify the ignition switch is in the "OFF"position, and

removethe negative battery cable from the battery.
® DONOTsoak componentsin any liquid cleaner or solvent;
this will damage them.
- Handle components carefully; any damagewill affect
proper operation of the EFt system.
¯ Makesure new componentshave the samepart number
as old ones; this will ensure proper engine performance.

Circuit Breakers
L.3J Volvo Penta EFI engineshave four circuit breakers as protection
devices.

A 12.5 ampcircuit breakerprotects the fuel injector relay

and ECM.
- A 50 ampcircuit breakerprotects the trim/tilt motor.
¯ A 80 ampcircuit breaker protects the main engine harness.
DR4640
A 20 ampcircuit breaker protects the fuel pumprelay and
circuit.
An additional 10 ampcircuit breaker located on the trim/tilt pumpprotects
the pumprelay. If one of these components or circuits fail, the ECM
will not
store a service code in memory.

Circuit Breaker Replacement

1. Makea note of the lead position, then removeall the leads from the
circuit breaker.Remove
the screwsand nuts, and lift the circuit breakerout
of the bracket.

2. Install a newcircuit breakerand secure with screwsand nuts. Tighten

the screwsto 20-25 in. Ibs. (2,3-2,8 N.m).

3. Attach the leadsto their original positions on the circuit breakerand

securewith the nuts. Tighten the nuts to 20-25in. Ibs. (2,3-2,8 N.m). Coat
the terminals with Liquid Neoprene.

Safety Related 8-2 Elect,;eng

inductor

The primary circuit pink wire, between the ignition coil and
distributor 2-wayterminal, contains an inductor to protect against
RFI interference, if the inductor fails, disconnectand replace 1:he
2-lead primary circuit wire harness.

Relay Replacement

Replacethe relay ~ by pulling it off its mountingbracket.

37872
Bnstall the relay by aligning the terminals of the retay with the
bracket, and pushingit in until it seats.

Engine Control Module (ECM)

Removal

Whenreplacing the ECM, or disconnecting the "Jl" or

"J2" connectors, the ignition switch must be "OFF" and the
battery must be disconnected. This will prevent damagingthe
ECM.
37544

To prevent possible electrostatic discharge damageto the

ECM,DONOTtouch the connector pins. The ECMis an electrilcal
componentthat can easily be damagedby static electricity. Do
not soak the ECMin any liquid cleaner or solvent; this will
damageit.

1. Removethe "Jl" ® and "J2" © connectors from the ECM

@.
~] 2. Unscrew four ECMmounting bolts ~. Remove the ECM
from the mounting bracket.
37545

Unstallation
~] t. Attach the new ECMto the mounting bracket and secure
with four screws. Tighten the screws to 88-124 in. Ibs. (10-14
N.m).

[~ 2. Attach the "Jl" ® and "J2" © connectors to the ECM.

Checkfor a secure attachment.

37547

37870
Elect/eng 8-3
 37551 37552 37553

EngineCoolant Temperature(ECT) Sensor

Removal

[~ 1. RemoveECTsensor electrical connector @.

[~ 2. UnscrewECTsensor ® from intake manifold.

Installation

1. Coat the ECTsensor threads with Volvo Penta White Sealing Com- 37554
pound P/N 1141570-0.

2. Install ECTsensor(~) into the intake manifold. Tighten sensor

108 in. Ibs. (12 N®m).

[~] 3. Attach ECTsensor electrical connector @.

ManifoldAbsolutePressure(MAP)Sensor
Removal

[~ 1. RemoveMAPsensor electrical connector @. 37555

[~ [~] 2. Unscrew two screws @securing MAPsensor (~ to upper

intake manifold. Remove
MAPsensor and seal (~).

37556

37558
8-4 E[ecveng
 37557 37559 37560

installation

EEl 1. Place a newseal ® on the MAPsensor.

[~E] 2. Install MAPsensoronto upperintake manifoldand secure
with two screws(~. Tightenscrewsto 44-62 in. Ibs. (5-7 N.m).

3. Attach MAPsensorelectrical connector©.

Throttle Position (TP) Sensor 37561

Removal

1. Remove flame arrestor from throttle bodyfollowing instruc-

tions found in GMEF! Fuel Systemsection of the Fuel Systems
Service Manual

[~] 2. RemoveTP sensor electrical connector@.

[~ I~ 3. Unscrewtwo screws® securing TP sensor to throttle
body. RemoveTP sensor and seal ~).
37562
installation

If replacing TP sensor, use newscrewsthat are supplied

with TP sensor service package.
[~ 1. Place TP sensorseal q~ over throttle shaft.

37563

375~
EIect/eng 8-5
 37565 37576 37577

E~ 2. verify that throttle plates are closed. Position TPsensoron throttle

shaft and align screwholes.

[~ 3. ~nstarl two retaining screwsA) and tighten to 18 in. Ibs. (2,0 N m).

4. Attach TPsensorelectrical connector(a).

Z~5. instain flame arrestor following instructions found in GMEF! FueJ

System section of the Fuel SystemsService Manual.

Intake Air Temperature(IAT) Sensor 37578

Removal

[~ 1. RemoveIAT sensor electrical connector ©.

E~ 2. Unscrew IAT sensor @from upper plenum.

Installation

1. Coat threads of IAT sensor with Volvo Penta White Sealing Compound
P/N 1141570-0.

2. Install IAT sensorinto upperplenumand tighten to 11 in. lbs. (15,0 37579

N.m).

E~ 3. Attach IAT sensor electrical connector @.

37580

37581
Safety ReJated 8-6 Elect/eng
Idle Air Control(iAC) Valve
Removal

1. Removeflame arrestor from throttle body folDowing instruc-

tions found in G/H EFI Fuel Systemsection of the Fuel Systems
Service Manual.

I~ 8"-8-~ 2. Remove
IACvalve electrical connector(~.

[~ 3. Unscrewtwo screws ® securing IAC valve to throttle

body. RemovemAC:valve @and discard O-ring. 37566

If an IAC valve has beenin service, DONOTpushor pull on

an IAC valve pintle. The force required to movethe pintle may
damagethe threads on the wormdrive. Also, DONOTsoak the
IAC valve in any biquid cleaner or solvent, this will damage
it.

Cleaning and Inspection

Both origina~ and replacement IAC valves have a special

factory locking compoundapplied to the screw threads. If the
valve removedfrom the throttle body is being reinstalled, DO
NOTremove the thread locking compoundthat may be on the 37567
threads.

Clean the IAC valve O-ring sealing surface, pintle valve seat and
air passage. Use carburetor cleaner to removecarbon deposits.
DO NOTuse a cleaner that contains methyl ethyl ketone, an
extremely strong solvent. It is not necessary for this kind of
deposit. Shiny spots on the pintle or seat are normal, and do not
indicate misalignrnent or a bent pintle shaft.

37568

Elect;eng 8-7
 DR5524 37569 37570

Installation

If installing a newIAC valve, be sure to replace old valve

with an identical part. IAC valve pintle shape and diameter are
designedfor a specific application.
E~ 1. if installing a new IAC valve, measure the distance
betweenthe tip of the valve pintle and the mountingsurface. If
greater than 1.102 in. (28 mm), use finger pressure to slowly
retract the pintle. Theforce required to retract the pintle of a new
valve will not cause damageto the new valve. 37571

[~ 2. Lightly lubricate a newO-ring (~ with engine oil and pmace

it on the IACvalve.
~[] 3. Install valve into throttle bodyand secure with two screws
®. Tighten screws to 28 in. Ibs. (3,2 N.m).

[~ 4. Attach IAC valve electrican connector @.

Z~ 5. Instal| flame arrestor following instructions found in GM
EFi Fuel Systemsection of the Fuel SystemsService Manual.
37572
6. Set IAC valve pintle position as follows:

¯ Start and run engine for 30 seconds

¯ Shut engine "OFF" for ten seconds
¯ Restart engine and check for proper idle operation

KnockSensor (KS)
Removal

[~ 1. Removeknock sensor electrical connector @.

37573

Safety Related 8-8 Elecbeng

 37574 37575 37598
L-6~ 2. Unscrewknock sensor (~ from engine block.

Installation

[~No--0~Install knocksensor in samelocation as old one. Makesure

threadsare clean. If installing knocksensorin a water jacket, coat threads
with VoEvoPenta White Sealing Compound P/N 1141570-0.

LT~ 1. Thread knocksensor ® into engine block and tighten to 11-16 ft.
Ibs. (15-22 N.m).

[._8~ 2. Attach knock sensorelectrical connector@. 37597

KnockSensor (KS) Module

Removal

[-9.~ 1. Remove
knock sensor moduIeelectrical connector ®.

[] 2. Unscrewtwo screws @securing knock sensor moduleto engine.

Removethe module.

installation
37598
[~ 1. Install knock sensor moduleon engine and secure with two screws
(~). Tighten screwssecurely.

2. Attach moduleelectrical connector(~.

37599

E[ect/eng 8-9
Relay OhmmeterTests
Throughoutthis section two symbols are used to interpret
electrical troubleshooting results.
[~ This symbol indicates continuity or very low resistance.

[~ This symbol indicates no continuity or very high resistance f

To avoid damagingcomponentsor troubleshooting equip-
ment, disconnect the battery cables from the battery and remove DR2065
the relays before proceeding.

1. Use a continuity light or ohmmetercalibrated on appropriate

scale to test continuity.
~] 2. Connect meter leads to relay terminals 87a and 30.

¯ The meter must show continuity.

DR2066

/
DR2149

8-10 ElecUeng
 70-100 ]

/____J
DR2149 DR2149 DR2149

[4---] 3. Connectmeter leads to relay terminals 87 and 30.

¯ The meter must show no continuity.

4. Calibrate an ohmmeteron appropriate scale and connect

the leads to relay terminals 85 and 86.

¯ The meter must show 70 - 100 ohms.

5. Connectmeter leads to relay terminals 87 and 30. Connect

a 12 volt source to relay terminals 85 and 86. DR214g

¯ The meter must show continuity.

[~ 6. Connect meter leads to relay terminals 87a and 30.

Connecta 12 volt source to relay terminals 85 and 86.

¯ The meter must show no continuity.

7. Replacerelay if your test results vary.

Circuit Breaker (nuts) ......................................... 20-25 in. Ibs. (2,3-2,8 N.m)

Circuit Breaker (screws) ....................................... 20-25in. Ibs. (2,3-2,8 N.m)
Engine Coolant Temperature (ECT) Sensor ............................. 108 in. Ibs. (12 N.m}
Engine Control Module (ECM) .................................. 88-124in. Ibs. (10-14 N.m}
Idle Air Control (IAC) Valve .......................................... 28 in. Ibs. (3,2 N.m}
Intake Air Temperature (IAT) Sensor ..................................... 11 ft. Ibs. (15 N.m)
Knock Sensor (KS} ............................................ 11-16ft. Ibs. (15-22 N.m}
Manifold Absolute Pressure (MAP) Sensor ........................... 44-62in. Ibs. (5-7 N.m}
Throttle Position (TP) Sensor ......................................... 18 in. Ibs. (2 N.m)

ElecUeng 8-11
 Notes
..........................................................................................
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 GMTBI

Table of Contents
Circuit Breakers ............................................ 8-14
Engine Control Module (ECM).................................. 8-15
Engine Coolant Temperature(ECT) Sensor ...................... 8-16
General information .......................................... 8-14
Idle Air Control (IAC) Valve .................................... 8-18
inductor .................................................... 8-15
Knock Sensor (KS) ........................................... 8-19
Knock Sensor (KS) Module .................................... 8-19
Manifold Absolute Pressure (MAP)Sensor....................... 8-16
Relay OhmmeterTests ........................................ 8-20
Relay Replacement........................................... 8-15
Throttle Position (TP) Sensor.................................. 8-17
Torque Specifications ........................................ 8-21

Safety Warnings
Beforeworkingon any part of the electrical system,read the section
called Safety at the end of this manual.

Theoriginal mounting,support androuting of the electrical systemparts

conformwith U. S. CoastGuardrequirements.It is important to maintain
the original mounting,supportandrouting after servicing the electrical
systemto preventpossible fire andexplosion in the boat’s engine
compartment.
Do not substitute automotiveparts. Volvo Pentamarine components
meetU.S. CoastGuardregulations for external ignition proof operation
and marine use. Volvo Penta marine components a~re specially designed
not: to causeignition of fuel vaporsin the bilge or enginecompartment.
Theuse of automotiveparts canresult in fire and explosion.
General Information
The ECBV!and all EF! sensorsare sensitive electronic components.
Observethe following cautions whenservicing them:

¯ Verify the ignition switch is in the "OFF"position, and

removethe negative battery cable from the battery.
¯ DONOTsoak componentsin any liquid cleaner or solvent;
this will damage
them.
¯ Handle components carefully; any damagewill affect
proper operation of the EFI system.
¯ Make sure new componentshave the same part number
as old ones; this will ensureproper engineperformance.

Circuit Breakers
r,==z=t
h~ Volvo Penta EFI engines have four circuit breakers as protection
devices.

A 12.5 ampcircuit breakerprotects the fuel injector relay

and ECM.
A 50 ampcircuit breakerprotects the trim/tilt motor.
A 60 ampcircuit breaker protects the main engine harness.
DR4640
A 20 ampcircuit breaker protects the fuel pumprelay and
circuit.
Anadditional 10 ampcircuit breakerlocated on the trim/tilt pumpprotects
the pumprefay. If one of these components
or circuits faiI, the ECM
will not
store a service code in memory.

Circuit Breaker Replacement

1. Makea note of the lead position, then removeall the leads from the
circuit breaker. Removethe screwsand nuts, and lift the circuit breakerout
of the bracket.

2. Install a newcircuit breaker and securewith screwsand nuts. Tighten

the screwsto 20-25in. Ibs. (2,3-2,8 Nora).

3. Attach the leads to their original positions on the circuit breakerand

securewith the nuts. Tighten the nuts to 20-25in. Ibs. (2,3-2,8 N.m). Coat
the terminals with Liquid Neoprene.

Z~ Safety Related 8-14 ElecUeng

 inductor
The primary circuit pink wire, between the ignition coil and
distributor 2-wayterminal, contains an inductor to protect against
RFI interference. If the inductor fails, disconnect and replace the
2-lead primary circuit wire harness.

Relay Replacement
Replacethe relay ® by pulling it off its mountingbracket.
Install the relay by aligning the terminals of the relay with the 37869

bracket, and pushthe relay in until it seats.

Engine Control Module(ECM)

Removal

Whenreplacing the ECM, or disconnecting the "Jl" or

"J2" connectors, the ignition switch must be "OFF" and the
~battery must be disconnected. This will prevent damagingthe
£CM.
37674

To prevent possible electrostatic discharge damageto the

ECM,DONOTtouch the connector pins. The ECMis an etectdc’al
componentthat can easily be damagedby static electricity. Do
not soak the ECMin any liquid cteaner or solvent; this will
damageit.

1. Remove
the flame arrestor cover and set it aside.

[~ 2. Removethe "Jl" ® and "J2" © connectors from the ECM

®.
[3 3. Removefour ECMmounting screws (~. Removethe ECM
from the mounting bracket.

[-~ 1. Attach the new ECMto the mounting bracket and secure
with four screws(E~. Tighten the screwsto 88-124in. Ibs. (10-14
N.m).
|oj 2. Attach the "Jl" (~ and "J2" © connectors to the ECM.
Checkfor a securE; attachment.

3. Install the flame arrestor cover. Tightenthe nut to 25-35in. Ibs. 37677
/2,8-4,0 N.m).

37673
E lect;eng 8-15
 37678 37679 3768O

Engine Coolant Temperature(ECT) Sensor

Removal

1. Disconnect electrical connector @from the ECTsensor.

~] 2. Removethe ECTsensor (~ from the thermostat housing.

Installation

1. Coat the ECTsensor threads with Volvo Penta White Seating Com- 37681

pound P/N 1141570=0.

2. Install ECTsensor (~ into the thermostat housing. Tighten sensor to 108

in. Ibs. (12 N,m).

3. Attach ECTsensorelectrical connectorA).

Manifold Absolute Pressure (MAP) Sensor

Removal

1. Remove
the flame arrestor cover from the engine. 37682

[~ 2. RemoveMAPsensor electrical connector @. Removethe "J2"

connector @from the ECM.

[~ 3. Unscrewtwo screws ~ securing MAPsensor ® to bracket.

RemoveMAPsensor.

~] 4. Loosen clamp @ and remove vacuum hose O from sensor.

37553

37654
8-1 6 ElecVeng
 37655 37656 37657

Installation
[~ 1. Attach vacuumhose ® to MAPsensor. Secure with clamp
@.
I[~ 2. Place MAPsensor (~ on bracket and secure with two
screws O. Tighten screws to 44-62 in. tbs. (5-7 N.m).

3. Attach MAPsensor enectrical connector ©, Attach the

"J2" electrical connector @to the ECM. Check for a secure
attachment. 37858

4. Install the flame arrestor cover. Tightenthe nut to 25-35in. Ibs.

(2,8-4,0 N.m).

Throttle Positiion (TP) Sensor

Removal

1. Removeflame arrestor cover from engine.

11~ 2. RemoveTP sensor electrical connector O. 37651

L~ [~] 3. Unscrewtwo screws @securing TP sensor to throttle

body. RemoveTP sensor and seal (g).

[Installation

If replacing TP sensor, use new screws that are supplied

with TP sensor service package.

[3 1. Place TP sensor seal ® on the TP sensor.

r~ 2. Verify that the throttle plates are closed. Position the rP
37666
sensor on the throttle shaft and align the screwholes. Install two
mounting screws @and tighten to 18 in. Ibs. (2 N.m).

:3. Install flame arrestor cover. Tighten the nut to 25-35 in. Ibs.
(2,8-4,0 N.m).

37661
Elect,’eng 8-17
 ©
©

37713 37714 37715

idle Air Control(IAC) Valve

Removal

1. Removeflame arrestor cover from the engine.

[~ 2. RemoveIAC valve electrical connector @.

[~ E~] 3. Removetwo screws ® securing IAC valve to throttle
body. RemoveIAC valve and discard O-ring @.
DR5524

Jf an mACvalve has beenin service, do not push or pull on

the IAC valve pintle. The force required to movethe pintle may
damagethe threads on the worm drive. Also, DONOTsoak the
DACvalve in any liquid cleaner or solvent, as damagemayresult.

Cleaning and inspection

Both original and replacement IAC valves have a special

factory locking compoundapplied to the screw threads. Uf the
vaKveremovedfrom the throttle body is being reinstalled, do not
removethe thread locking compoundthat maybe on the threads.
37716
Cleanthe nACvaRvegasket sealing surface, pintle valve seat and
air passage. Use carburetor cleaner to removecarbon deposits.
DO NOTuse a cleaner that contains methyl ethyl ketone, an
extremely strong solvent. It is not necessary for this kind of
deposit. Shiny spots on the pintle or seat are normal, and do not
indicate misalignmentor a bent pintle shaft.

installation

If installing a newDACvalve, be sure to replace it with an

identical part. The IAC valve pintle shape and diameter are
designedfor the specific application. 37717

[~ 1. Measurethe distance between the tip @of the IAC valve

pintle and the mountingsurface (~. If the measurement is greater
than 1.102 in. (28 mm),use finger pressure to slowly retract the
pintle. Theforce required to retract the pintle of a newvalve wilU
not cause damageto the valve.

Safety Related 8-18 Elect/eng

 37718 37719 37720

[=5=_.~~ 2. Lightly lubricate a newO-ring (~ with engineoil and place it

on the IAC valve. Install the valve into the throttle bodyandsecurewith two
screws(~. Tighten the screwsto 28 in. Ibs. (3.2 N.m).

[:7-=7 3. Attach the IAC valve electrical connector@.Checkfor a secure

attachment.

4. Install flamearrestor cover. Tightenthe nut to 25-35in. Ibs. (2,8-4,0

Nom).

KnockSensor (KS) 37721

Removal

["8-’] 1. Remove
knocksensor electrical connector@.

[~ 2. Unscrewthe knock sensor ® from the engine block. Use a backup

wrenchto keep the %fitting from rotating.

installation

[~O-O-~Install the knocksensor in the samelocation as the old one. Make

sure the threadsare clean. If installing the knocksensorin a water jacket, 37722
coat the threads with Volvo Penta White Sealing Compound P/N 1141570- \
0.

~=_.~ 1. Threadthe knock sensor ® into the engine block and tighten to
11-16ft. Ibs. (15=22N,,m). Usea wrenchto keepthe T-fitting fromrotating.

[~ 2. Attach the knock sensor electrical connector @.

KnockSensor ([KS) Module

Flemoval
37693
1. Remove
the flame arrestor cover from the engine.

[’~ 2. Removethe knock sensor moduleelectrical connector Q.

 3769<, 37695 37696

[~ 3. Unscrew the two screws @securing the knock sensor

module to the engine. Remove the module ®.

installation
[~ 1. Install the knock sensor module ® on the engine and
secure with two screws (~o Tighten the screws securely.

[~ 2. Attach the module electrical connector ©.

3. InstalU the flame arrestor cover and tighten the nut to 25-35in. DR2065
Ibs. (2,8-4,0 N.m).

Relay OhmmeterTests
[~ Throughout this section two symbols are used to interpret
electrical troubleshooting results.

This symbol indicates continuity or very low resistance.

This symbolindicates no continuity or very high resistance

DR2066

[~ To avoid damaging components or troubleshooting equip-

ment, disconnect the battery cables from the battery and remove
the relays before proceeding.

1. Use a continuity light or ohmmetercalibrated on appropriate

scale to test continuity=

2. Connectmeter ieads to relay terminals 87a and 30.

¯ The meter must show continuity.

149

8-20 EIecUeng
 i
DR2149

[~ 3. Connect meter leads to relay terminals 87 and 30.

e The meter must show no continuity.

[~ 4. Calibrate an ohmmeteron appropriate scale and connect

the leads to relay terminals 85 and 86.

o The meter must show 70 - 100 ohms.

5. Connectmeter leads to relay terminals 87 and 30= Connect

a 12 volt source to relay terminals 85 and 86. D,2149

¯ The meter must show continuity.

[~ 6. Connect meter leads to relay terminals 87a and 30.
Connecta 12 volt source to relay terminals 85 and 86.

e The meter must show no continuity.

7. Replacerelay if your test results vary.

Circuit Breaker (nuts) ......................................... 20-25 in. Ibs. (2,3-2,8 N.m)

Circuit Breaker (screws) ....................................... 20-25in. Ibs. (2,3-2,8 N.m)
Engine Coolant Temperature (ECT) Sensor ............................. 108 in. Ibs. (12 N.m)
Engine Control Module (ECM) .................................. 88-124in. Ibs. (10-14 N.m)
Flame Arrestor Cover ......................................... 25-35in. Ibs. (2,8-4,0 N.m)
Idle Air Control (IAC) Valve .......................................... 28 in. Ibs. (3,2 N.m)
intake Air Temperature (IAT) Sensor .................................... 11 ft. Ibs. (15 N-m)
Knock Sensor (KS) ............................................. 11-16ft. Ibs. (15-22 N.m)
Manifold Absolute Pressure (MAP) Sensor ........................... 44-62in. Ibs. (5-7 N-m)
Throttle Position (TP) Sensor ......................................... 18 in. Ibs. (2 N.m)

E.ect,
eo, 8-21
 Notes
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 Section 9
Electrical System Wiring Diagrams
All Models

Table of Contents

3.0 GS ..................................................... 9-2

4.3GL and GS .............................................. 9-4
5.TGL and GS .............................................. 9-6
4.3Gi and 5.7Gi, GSi ......................................... 9-8
7..4 GL .................................................... 9-10
7.4 Gi, GSi and 8.2 GSi ...................................... 9-12
Engine Cable Wiring Diagram
3.0GS

(~) Trim Sender

(~) WaterTemperatureSender, Gauge
(~) Water TemperatureSwitch, Audible Alarm*
(~) Relay Control Box, Trim Motor
(~) 10 AmpCircuit Breaker
(~) Starter Relay
0 Insturment HarnessCircuit Breaker
(~)Trim/Tilt Circuit Breaker
(~) Oil Pressure SendingUnit, Gauge
EWectricChoke,Carburetor
[~ Oil PressureSwitch, Audible Alarm*
(~ Inductor

9-2 Elec~eng
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 Safety Section

Part A
Marine Products and Safety of People Who Use Them . . . . . . . . . S-2
Sterndrive Shift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3
Sterndrive Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . S-4
Sterndrive Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Sterndrive Fuel, Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . S-7

Part B
Marine Products and Safety of People Who Fix Them . . . . . . . . S-11
Handling Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-11
Handling Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12
Gasoline! Handle with Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13
Hazardous Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14

Safety
S-1
 Part A - Marine Products and safety of
People Who Use Them

Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are
careful to make sure...

Product User is informed. . .

Products are safe and reliable. . .

It's up to you, the People who. . .

Install accessories. . .

Service and Maintain the boat. . .

Service and maintain the sterndrive. . .

. . . to keep the products safe and reliable.

This section talks about safe boating and how you can help keep it safe. Some things you may know
. . . but others you may not.

First!

A word about fasteners . . . plain . . . special . . . all screws, nuts, washers and bolts.

Do Not Substitute Fasteners

They look the same, but . . . are they?

The Same Size?

The Same Strength?
The Same Material?
The Same Type?
Standard or Metric Thread?

Don't substitute unless you know they are the same in all characteristics.

Second!

Special locking screws and nuts are often used to attach steering, and remote control components to
the sterndrive.

When you remove any part from the sterndrive, keep track of special screws and nuts. Don't mix with
other parts

When reassembling the sterndrive, use only the special screws and nuts intended to hold steering, and
control cables, plus related parts.

Service with parts of known quality that meet Marine Industry (BIA/ABYC) Standard.

S-2 Safety
 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
 Sterndrive Throttle Control System

The throttle Control System starts

here and the remote control lever . . .
. . . and ends
here on the engine.

What's Most Important?

When the control lever is moved from

Forward (or Reverse) to Neutral . . .
. . . engine speed must slow to idle
RPM and allow operator to shift into
Neutral.

Operator must be able to stop propeller.

What Could Happen?

If operator cannot slow the engine to idle RPM and shift into neutral, (stop propeller), operator could panic and lose control
of boat.

How Can Loss of Throttle 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 engine throttle response is smooth.

Make sure full throttle operating RPM can be reached so operator won't overload engine

S-4 Safety
 Sterndrive Steering System

The Steering System starts

here at the helm . . .

What's Most Important?

The Steering System . . .

. . . and ends here at the propeller
on the sterndrive
must be installed properly

must be adjusted properly

must be lubricated

What Could Happen?

. . . if steering system comes apart, boat would turn suddenly and circle . . . passengers and/or operator
may be thrown into water and could be hit.

. . . if steering jams, operator may not be able to avoid obstacles. Operator could panic.

. . . if steering is loose, operator may not be able to maintain a true course, and could result in loss of
boat control.

Safety
S-5
 How Can Loss of Steering Control be Minimized?

In pre-
use steering components which meet marine industry (BIA/ABYC) standards . . .
delivery Read, understand, and follow manufacturer's instructions.
inspection Assemble parts and make adjustments carefully . . .
and when Closely follow the warnings marked with ...
servicing Keep parts moving freely . . . lubricate parts as soon as shown in manuals
Use bolts, nuts, and washers supplied with steering attachment kits

When power assisted or mechanical steering systems are used, check to uncover possible trouble!

Cable housing in this area

must not be restricted Steering components must not
bind
Why? Unit may go to full turn without
Why? Possible jamming of steering
turning steering wheel (Power
system.
assist models)

Engine stringer must not interfere

with power steering pump and pul-
ley

Maintain proper belt tension.

Power steering parts and push/pull cable

must be free to move in order to actuate
power steering valve when operator
turns steering wheel

Check for damaged parts . . . impacts to the sterndrive like this

or this . . . or ? ? ?
can put stress on steering components. Look for . . .

Cracked parts
Bent parts
Loose fasteners

Replace damaged parts. If weakened, parts could fail later . . . on the water
. . . when least expected.

S-6 Safety
 Sterndrive Fuel and Electrical Systems

The electrical System begins

here at the battery . . .
. . . and ends here
at the carburetor or fuel injectors

The fuel system

starts here at the fuel tank . . . . . . and ends
here on the en-
gine.

What's Important?

Fuel leakage must be prevented.

Electric sparks must not happen.

What Could Happen?

Gasoline can explode and/ or burn easily:

When boating, fuel leaking in the engine compartment could be ignited by a spark from a loose wire
connection, or a damaged or deteriorated electrical component.

How Can Fire and Explosion Be Minimized?

Read, understand and follow manufacturers instructions.

Closely follow the warnings marked with ...

Do not substitute fuel or electrical parts with other parts which may look the same. These parts are
designed and manufactured to meet special U. S. Coast Guard safety regulations to prevent fire and
explosion.

If you work on marine engines, you must understand these U.S. Coast Guard requirements. If you don't have them, write
to . . .

---------
---------
---------
National Technical Information Service
Springfield, Virginia 22161
. . . and ask for copies of:

(1) Electrical System Compliance Guideline (AD/A-049-638)

(2) Fuel System Compliance Guideline (AD/A-047-767)
These are concise guidelines - easy to read and understand. They explain what must be done to prevent fire and explo-
sions.

Safety
S-7
 Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard require-
ments. Most automotive parts do not, especially electrical components that must meet ignition protec-
tion requirements of the U.S. Coast Guard regulations.

When nonmetallic parts look to be in poor shape . . . replace them!

Torn Boots!
Wires Cracked!

Cracked Fuel Lines!

Using parts which meet U.S. Coast guard requirements is only half the job. The other half is your job . . .

It's time for replacement BEFORE sparks and/or fuel leaks occur.

Replace parts carefully. Make sure nuts and bolts are tight especially when they anchor electrical wires
(to prevent sparking). If lock washers are specified - use them. No short cuts or missing parts with
either of these CRITICAL safety related systems.

When refueling, always ground fuel nozzle to the inlet fitting on the boat to prevent the buildup of
electrostatic sparks. If you use a funnel, make sure it's metal and ground the fuel nozzle to the funnel.

If you smell gasoline in the engine compartment . . .

STOP find its source and stop the leakage.

S-8 Safety
 Follow "Starting Procedure" outlined in the operator's manual.

Always make sure there are no gasoline fumes in the engine compartment before starting the
engine. Open the compartment and use your nose. Don't gamble.

Backfire flame arrestor must be in place and securely attached to the air intake.

Do not alter the backfire flame arrestor.

If loose, damaged, or altered, an engine "backfire" may pass through the flame arrestor assembly into the engine compart-
ment. If fumes are present in compartment, fire and explosion could result.

Safety
S-9
Summing Up

Now you know some things that can take the joy out of enjoyable boating.

No doubt about it . . . it takes time!

Reading and understanding instructions.

Reading and understanding warnings marked with ...

Putting parts together correctly . . .

Making correct adjustments . . .

Testing you work.

and making sure

Worn or damaged parts are replaced,

Replaced parts are like originals . . . in every way.

Customer is told of things which need attention . . .

But do you really want the alternative?

S-10 Safety
 Part B - Marine Products and Safety of
People* Who Fix Them

Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you?
Mechanics can be hurt while . . .

Servicing boats
Servicing sterndrives
Troubleshooting problems
Testing their work

Some items you'll know . . . others you may not.

When Lifting Engines

If hoist is poor shape . . . or too small for the job

Engine may drop suddenly

DR3471 DR3469

Make sure shop aids have extra capacity — and keep them in good repair!

When Running Engine with Engine Compartment Cover Removed

The engine compartment cover is a guard. When you remove the cover / guard to work on the engine, remember:

Loose clothing (open shirt sleeves, neckties), long hair, jewelry (rings, watches, bracelets), hands,
arms, belts can be caught by moving belts or spinning pulleys
Handle high voltage ignition components carefully. They can shock you and may cause you to recoil into
moving parts.

Two people working together on a running engine must look out for each other. Never, ever, hit the key to start the
engine before signalling to your partner. (He may be leaning over the engine with his hands on a belt, or a "hot" electri-
cal part, near the propeller, etc.)

*Mechanics, technicians, backyard do-it-yourselfers.

Safety
S-11
 Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . .
you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly!
When you smell the other gasses in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated
areas.

Eyes Need help

Grinding Sprayed
Cleaners,
Paints

End of Cables Acid

Chiseling
(steel on steel)
(Tip: Use plastic or brass type hammers.
They don't chip off as easily as steel hammers.)

Handling Lead Acid Batteries

If spilled or splashed on
any part of body..

Wash with lots

If solution gets
of water. . .
into eyes. . .
Wash. . . and see a Doctor, fast!

Charging Lead Acid Batteries

Attach and remove these cables

with charger unplugged from 110 volt wall
socket. (Prevents shocks if the charger
is defective.)

Observe correct polarity when con-

necting these charger leads.

Always charge in a well ventilated

area. Charging causes acid solution to
give off hydrogen gas through the vents
in the caps. . . Make sure vents are open.
If clogged, pressure inside may build. . .
battery may explode.

S-12 Safety
 Never yank cables off
Battery gas is explosive! battery posts. . . it's a sure
While charging or discharging, way to make lots of
remember. . . sparks. . .surrounded by battery gas

No Smoking
No Flames
No Sparks

Don't check battery condition After Charging. . .

by placing metal objects
across posts. Shut off charger

You're sure to make sparks Remove charger plug from wall socket
Then. . .
and serious burns are
possible. Take charger cable off battery posts

Gasoline! Handle With Care

When you smell any odor of gasoline,
explosion is possible

Gasoline fumes are heavier than air and will sink

to the lowest point in the boat or room,
and will stay there. . . waiting

Gasoline explodes easily and violently when

If the air around you is quiet . . . the pilot light in mixed with air
the heater may
ignite the heavy fumes 5 Parts
before your nose ever Gasoline
smells the fumes . .
100 Parts
Air

What Can you Do?

Store properly . . .
Fill portable tanks outside boat to prevent spillage in
boat
Use fuel for fuel . . . not for a solvent
If fumes are smelled (in shop, basement, garage), immediately:
Store in sturdy, Put out open flames, cigarettes, sparking devices
sealed gas can Wipe up spill or leak; get towels, rags outside fast
. . .and . . . Check lowest area for fumes; open doors or win-
keep outside dows

Safety
S-13
 Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled.

Matches, cigarettes, torches, welders

Electric motors (with unsealed cases)
Electric generators (with unsealed cases)
Light switches
Appliance pilot lights (furnace, dryer, water heater)
?????????
How many of these are in your area?

Hazardous Products

Read the container label. It tells you . . .

"How, and where, to use,"

"How to give First Aid," and have "recommended" first aid materials on hand- should an
emergency arise
"How to dispose of can,"

Remember: Little children are very curious and will try to taste everything, so . . .

. . . yummmmmmmmmmm Keep containers away

from children

S-14 Safety
 7 /"- .......... ~

33
VOLVOPENTAMODELiDENTIFiCATION

EngineModelidentification is located on the engine valve cover for four cylinder (in-line) models,
on the inside of the port valve cover for V6 & V8 models, or on the Thick Film Ignition (TFI)
module bracket for Ford fuel injection models. The identification numbersmust correspond with
the transom shield and drive unit numbers. See below.

Engine Model Number(GL, GS, and Gi Models)

Engine Model Number

SX MODELS:

[~ Transom Shield Model Number

[~ Drive Unit Model Number

DP & DPX MODELS:

Nunber plate for drive unit andtransomshield,

Onlyfields 2 and3 are filled for transom
shield.

1 4
3

1. Product Designation
2. Model Number
3. Serial Number
4. Reduction Ratio