Volvo Penta 4.3GL GXi OSi-A B C D E Engine Workshop Manual_74550500 – PDF DOWNLOAD

Volvo Penta 4.3GL GXi OSi-A B C D E Engine Workshop Manual_74550500 – PDF DOWNLOAD

DESCRIPTION:

Volvo Penta 4.3GL GXi OSi-A B C D E Engine Workshop Manual_74550500 – PDF DOWNLOAD

4.3GL-A/B/C/D
4.3GXi-A/B(F)/C(F)/D(F)/E(F)
4.30Si-B(F)/C(F)/D(F)/E(F)

General Information
This service manual is divided into sections concerning various systems
and assemblies. Refer to the Contents to locate the section covering
the system or assembly requiring service. Each section title page
has an additional listing that will describe the sections contents in
more detail. Be sure to read the Safety Section at the end of this manual,
and pay special attention to all safety warnings as they appear
throughout the text. Since models are subject to change at any time,
some photos may not depict actual product.
Good Service Practice Service required for stern drives is generally one of three kinds:
• Normal care and maintenance – which includes putting a new
stern drive into operation, storing engines, lubrication, and care
under special operating conditions such as salt water and cold
weather.
• Operating malfunctions – due to improper engine or drive
mounting, propeller condition or size, boat condition, or the malfunction
of some part of the engine. This includes engine servicing
procedures to keep the engine in prime operating condition.
• Complete disassembly and overhaul – such as major service
or rebuilding a unit.
It is important to determine before disassembly just what the trouble is
and how to correct it quickly, with minimum expense to the owner.
When repairing an assembly, the most reliable way to ensure a good
job is to do a complete overhaul on that assembly, rather than just to
replace the bad part. Wear not readily apparent on other parts could
cause malfunction soon after the repair job. Repair kits and seal kits
contain all the parts needed to ensure a complete repair, to eliminate
guesswork, and to save time.
Repair time can also be minimized by the use of special tools. Volvo
Penta special tools are designed to perform service procedures
unique to the product that cannot be completed using tools from other
sources. They also speed repair work to help achieve service flat rate
times. In some cases, the use of substitute tools can damage the part.
Preparation for Service Proper preparation is extremely helpful for efficient service work. A
clean work area at the start of each job will minimize tools and parts
becoming misplaced. Clean an engine that is excessively dirty before
work starts. Cleaning will occasionally uncover trouble sources. Obtain
tools, instruments and parts needed for the job before work is started.
Interrupting a job to locate special tools or repair kits is a needless
delay.

TABLE OF CONTENTS:

Volvo Penta 4.3GL GXi OSi-A B C D E Engine Workshop Manual_74550500 – PDF DOWNLOAD

ChapterTitleTOC – General Information 1………………………………………. 3
ChapterTitleTOC – General Mechanical 29………………………………………. 3
ChapterTitleTOC – Engine – 4.3 Liter 53………………………………………. 3
ChapterTitleTOC – Steering System 175………………………………………… 3
ChapterTitleTOC – Throttle & Shift Control System 197………………………….. 3
ChapterTitleTOC – Cooling System 205…………………………………………. 3
ChapterTitleTOC – Engine Removal and Installation 225………………………….. 3
Heading1 – Model Identification……………………………………………… 4
Heading1 – Engine Model Number………………………………………………. 4
Heading3 – ……………………………………………………………. 4
Heading3 – ……………………………………………………………. 4
Heading1 – Emission Control Labels…………………………………………… 5
Heading3 – 4.3GL……………………………………………………….. 5
Heading1 – Transom Shield Model Number Location……………………………….. 6
Heading3 – ……………………………………………………………. 6
Heading1 – Sterndrive Model Number Location…………………………………… 6
Heading3 – ……………………………………………………………. 6
Heading3 – ……………………………………………………………. 6
ChapterTitle – Section 1: General Information…………………………………. 7
Heading3 – Good Service Practice…………………………………………. 8
Heading3 – Preparation for Service……………………………………….. 8
Heading3 – Service Policy……………………………………………….. 8
Heading3 – Replacement Parts…………………………………………….. 9
Heading3 – Parts Catalogs……………………………………………….. 9
Heading3 – Special Service Tools…………………………………………. 9
Heading3 – Product References, Illustrations & Specifications……………….. 9
Heading1 – Tuning the Engine…………………………………………….. 10
Heading2 – Engine Compression Testing…………………………………. 10
Heading2 – Test Conclusion…………………………………………… 10
Heading2 – Ignition System Components…………………………………. 11
Heading2 – Fuel System Components…………………………………….. 11
Heading2 – Intake Manifold Vacuum Testing……………………………… 12
Heading3 – Test Procedures…………………………………………… 12
Heading3 – Test Results……………………………………………… 12
Heading2 – Gasoline Requirements……………………………………… 14
Heading2 – Gasoline Containing Alcohol………………………………… 14
Heading1 – Crankcase Oil………………………………………………… 15
Heading3 – Draining and Filling the Engine Crankcase……………………. 15
Heading3 – Oil Filter……………………………………………….. 16
Heading1 – Steering System Lubrication……………………………………. 16
Heading1 – Power Trim/Tilt Fluid Level……………………………………. 16
Heading1 – Off-Season Storage……………………………………………. 17
Heading3 – Limited Use………………………………………………. 17
Heading3 – Storage………………………………………………….. 17
Heading3 – Step 1. Prepare a storage mixture…………………………… 17
Heading3 – Electric Fuel Pumps and Fuel Cells………………………….. 18
Heading3 – Stuck Pumps………………………………………………. 18
Heading3 – Noisy Fuel Pumps………………………………………….. 18
Heading3 – Step 2. Change Motor Oil and Oil Filter:…………………….. 19
Heading3 – Step 3. Change Sterndrive Lubricant:………………………… 19
Heading3 – Step 4. Fog Engine:……………………………………….. 19
Heading3 – Step 5. Drain Cooling System……………………………….. 19
Heading1 – Preparation for Boating After Storage…………………………… 19
Heading1 – Engine Break-in………………………………………………. 20
Heading3 – First Two Hours…………………………………………… 21
Heading3 – Next Eight Hours………………………………………….. 21
Heading3 – Final Ten Hours…………………………………………… 21
Heading3 – Operation After Break-in…………………………………… 22
Heading1 – Submerged Engine……………………………………………… 22
Heading1 – 20-Hour Check………………………………………………… 22
Heading1 – Belt Tension…………………………………………………. 23
Heading3 – ………………………………………………………… 23
Heading2 – Alternator Belt Adjustment…………………………………. 23
Heading3 – ………………………………………………………… 23
Heading2 – Power Steering Pump Belt Adjust ment………………………… 24
Heading3 – ………………………………………………………… 24
Heading1 – Positive Closed-Type Ventilation System (4.3GXi-A only)…………… 24
Heading3 – With Engine Idling………………………………………… 25
Heading3 – With Engine Stopped……………………………………….. 25
Heading3 – Servicing PCV Valve……………………………………….. 25
Heading1 – Troubleshooting – System Isolation……………………………… 25
Heading1 – Engine Troubleshooting Guides………………………………….. 25
Heading2 – Engine Will Not Crank……………………………………… 27
Heading3 – Starter Circuit – Check:…………………………………… 27
Heading2 – Engine Cranks, But Will Not Start…………………………… 27
Heading3 – Ignition Circuit – Check:………………………………….. 27
Heading3 – Fuel System – Check:………………………………………. 27
Heading3 – Cylinder Compression – Check……………………………….. 28
Heading2 – Hard Starting – Cold Engine………………………………… 28
Heading3 – Has Engine Always Done This? Check:…………………………. 28
Heading3 – Was Engine Used For A Long Time? Check:……………………… 28
Heading3 – Is This A New Condition? Check:…………………………….. 28
Heading2 – Hard Starting – Hot Engine…………………………………. 28
Heading3 – Has Engine Always Done This? Check:…………………………. 28
Heading3 – Is This A New Condition? Check:…………………………….. 28
Heading3 – Did Engine Refuse To Start After Being Run? Check:……………. 28
Heading2 – Engine Runs Rough…………………………………………. 29
Heading3 – If At Slow Speed – Check:………………………………….. 29
Heading3 – If At High Speed – Check:………………………………….. 29
Heading2 – Engine Noises and Vibrations……………………………….. 29
Heading3 – Valves – Hydraulic Lifters…………………………………. 29
Heading3 – Ignition System (Ping or Knock)…………………………….. 29
Heading3 – Cooling System……………………………………………. 29
Heading3 – Mountings………………………………………………… 30
Heading3 – Crankshaft Balancer or Flywheel…………………………….. 30
Heading3 – Alternator……………………………………………….. 30
Heading3 – Sterndrive……………………………………………….. 30
Heading2 – Engine Overheats – Check:………………………………….. 30
Heading2 – Engine Dies Out…………………………………………… 30
Heading3 – Loss Of, Or Out Of, Fuel – Check:…………………………… 30
Heading3 – Loss Of Ignition – Check:………………………………….. 30
Heading3 – Engine Stops Or Dies Out Due To Seizure – Check:……………… 31
Heading2 – Engine Won’t Reach Operating RPM – Check:……………………. 31
Heading2 – Defective Engine Lubricating System…………………………. 31
Heading3 – Engine Components – Check:…………………………………. 31
Heading3 – Oil Pressure Warning System – Check:………………………… 31
Heading2 – Low Battery Voltage After Short Stor age…………………….. 32
Heading3 – Engine/Boat Components – Check:…………………………….. 32
Heading1 – General Engine Specifications………………………………….. 33
Heading2 – 4.3GL-A/B/C/D…………………………………………….. 33
Heading3 – Battery size……………………………………………… 33
Heading3 – Bore and stroke…………………………………………… 33
Heading3 – Carburetor (GL)…………………………………………… 33
Heading3 – Charging system…………………………………………… 33
Heading3 – Cooling system……………………………………………. 33
Heading3 – Cylinders (number)………………………………………… 33
Heading3 – Displacement……………………………………………… 33
Heading3 – Firing order……………………………………………… 33
Heading3 – Fuel filter………………………………………………. 33
Heading3 – Fuel type………………………………………………… 33
Heading3 – Full throttle operating range………………………………. 33
Heading3 – Idle RPM…………………………………………………. 33
Heading3 – Ignition timing…………………………………………… 33
Heading3 – Oil capacity……………………………………………… 33
Heading3 – Engine Oil filter…………………………………………. 33
Heading3 – Oil type…………………………………………………. 33
Heading3 – Power steering fluid………………………………………. 33
Heading3 – Spark plugs………………………………………………. 33
Heading3 – Spark plug gap……………………………………………. 33
Heading3 – Spark plug installation torque……………………………… 33
Heading2 – 4.3GXi-A/B/C/D/E………………………………………….. 34
Heading3 – Battery size……………………………………………… 34
Heading3 – Bore and stroke…………………………………………… 34
Heading3 – Charging system…………………………………………… 34
Heading3 – Cooling system……………………………………………. 34
Heading3 – Cooling System Capacity (F) Series………………………….. 34
Heading3 – Cylinders (number)………………………………………… 34
Heading3 – Displacement……………………………………………… 34
Heading3 – Firing order……………………………………………… 34
Heading3 – Fuel filter………………………………………………. 34
Heading3 – Fuel type………………………………………………… 34
Heading3 – Full throttle operating range………………………………. 34
Heading3 – Idle RPM…………………………………………………. 34
Heading3 – Ignition timing…………………………………………… 34
Heading3 – Oil capacity……………………………………………… 34
Heading3 – Engine Oil filter…………………………………………. 34
Heading3 – Oil type…………………………………………………. 34
Heading3 – Power steering fluid………………………………………. 34
Heading3 – Spark plugs………………………………………………. 34
Heading3 – Spark plug gap……………………………………………. 34
Heading3 – Spark plug installation torque……………………………… 34
ChapterTitle – Section 2: General Mechanical………………………………….. 35
Heading1 – General Description…………………………………………… 35
Heading1 – Cleanliness and Care………………………………………….. 36
Heading1 – Use of RTV Sealer and Anaerobic Gasket Eliminator………………… 36
Heading3 – Using RTV Sealer………………………………………….. 36
Heading3 – Using Anaerobic Gasket Eliminator…………………………… 37
Heading1 – Replacing Engine Gaskets………………………………………. 37
Heading1 – Cylinder Bores……………………………………………….. 38
Heading3 – Measuring Cylinder Bore Taper and Out-of-Round……………….. 38
Heading3 – ………………………………………………………… 38
Heading3 – ………………………………………………………… 38
Heading3 – Cylinder Bore Reconditioning……………………………….. 38
Heading3 – ………………………………………………………… 38
Heading3 – Removing Cylinder Bore Ridge……………………………….. 39
Heading3 – ………………………………………………………… 39
Heading3 – ………………………………………………………… 39
Heading3 – Boring…………………………………………………… 39
Heading3 – Honing…………………………………………………… 40
Heading3 – ………………………………………………………… 40
Heading1 – Piston and Connecting Rod……………………………………… 41
Heading3 – Disassemble:……………………………………………… 41
Heading3 – Piston Pin……………………………………………….. 41
Heading3 – Clean:…………………………………………………… 41
Heading3 – Inspect:…………………………………………………. 42
Heading1 – Measuring Piston Pin to Piston Clearance………………………… 42
Heading3 – Measure:…………………………………………………. 42
Heading3 – Piston pin diameter……………………………………….. 42
Heading3 – Piston pin to piston clearance……………………………… 42
Heading1 – Piston Selection……………………………………………… 43
Heading3 – Check the used piston to cylinder bore clearance……………… 43
Heading3 – Measure:…………………………………………………. 43
Heading1 – Assembling the Piston and Connecting Rod………………………… 43
Heading3 – Assemble:………………………………………………… 44
Heading1 – Installing the Piston Rings……………………………………. 44
Heading3 – Measure:…………………………………………………. 44
Heading3 – Inspect:…………………………………………………. 45
Heading3 – Assemble:………………………………………………… 45
Heading3 – Measure:…………………………………………………. 45
Heading1 – Camshaft Bearings…………………………………………….. 46
Heading2 – Camshaft Bearing Removal…………………………………… 46
Heading3 – Disassemble:……………………………………………… 46
Heading3 – Cleaning and Inspection……………………………………. 46
Heading3 – Clean:…………………………………………………… 46
Heading3 – Inspect:…………………………………………………. 46
Heading2 – Camshaft Measurements……………………………………… 46
Heading3 – Measure:…………………………………………………. 47
Heading3 – Assemble:………………………………………………… 47
Heading1 – Cylinder Head………………………………………………… 48
Heading3 – Disassemble………………………………………………. 48
Heading3 – Cleaning and Inspection……………………………………. 48
Heading3 – Clean……………………………………………………. 48
Heading3 – Inspect………………………………………………….. 49
Heading3 – Measure:…………………………………………………. 49
Heading3 – ………………………………………………………… 49
Heading3 – ………………………………………………………… 50
Heading3 – Repair…………………………………………………… 50
Heading2 – Valve Grinding……………………………………………. 50
Heading3 – Valve Seat Grinding……………………………………….. 50
Heading3 – Reaming Valve Guides………………………………………. 51
Heading3 – Assembly…………………………………………………. 51
Heading2 – Valves and components……………………………………… 51
Heading3 – Measure:…………………………………………………. 51
Heading1 – Crankshaft and Connecting Rod Bearings………………………….. 51
Heading3 – Cleaning and Inspection……………………………………. 51
Heading3 – Clean:…………………………………………………… 51
Heading3 – Inspect:…………………………………………………. 52
Heading3 – Measuring Bearing Clearance………………………………… 52
Heading3 – Micrometer Method…………………………………………. 52
Heading3 – Plastic Gauge Method………………………………………. 53
Heading3 – Crankshaft Runout…………………………………………. 53
Heading3 – Measure:…………………………………………………. 53
Heading3 – Connecting Rod Side Clearance………………………………. 54
Heading3 – Measure:…………………………………………………. 54
Heading3 – Crankshaft End Play……………………………………….. 54
Heading3 – Measure:…………………………………………………. 54
Heading3 – Inspect:…………………………………………………. 54
Heading1 – Thread Repair………………………………………………… 54
Heading1 – Special Tools………………………………………………… 56
ChapterTitle – Section 3: Engine – 4.3 Liter………………………………….. 59
Heading1 – General Description…………………………………………… 60
Heading3 – Engine Construction……………………………………….. 60
Heading3 – Cylinder Block……………………………………………. 60
Heading3 – Cylinder Heads……………………………………………. 61
Heading3 – Crankshaft……………………………………………….. 61
Heading3 – Camshaft…………………………………………………. 61
Heading3 – Pistons and Connecting Rods………………………………… 61
Heading3 – Balance Shaft…………………………………………….. 61
Heading3 – Valve Train………………………………………………. 61
Heading3 – Intake Manifold…………………………………………… 61
Heading1 – Tools and Shop Equipment………………………………………. 61
Heading1 – Accessories………………………………………………….. 62
Heading1 – Cleaning…………………………………………………….. 62
Heading1 – Draining The Engine…………………………………………… 62
Heading1 – Engine Lubrication……………………………………………. 63
Heading1 – Exhaust Manifold……………………………………………… 63
Heading3 – Removal………………………………………………….. 63
Heading3 – Inspection……………………………………………….. 64
Heading3 – Installation……………………………………………… 64
Heading3 – ………………………………………………………… 64
Heading3 – ………………………………………………………… 65
Heading3 – ………………………………………………………… 65
Heading3 – ………………………………………………………… 65
Heading1 – Starter……………………………………………………… 66
Heading3 – Remove…………………………………………………… 66
Heading3 – ………………………………………………………… 66
Heading3 – Installation……………………………………………… 66
Heading3 – ………………………………………………………… 67
Heading1 – Intake Manifold………………………………………………. 67
Heading3 – Removal………………………………………………….. 67
Heading3 – ………………………………………………………… 67
Heading3 – ………………………………………………………… 68
Heading3 – ………………………………………………………… 68
Heading3 – Disconnect:………………………………………………. 68
Heading3 – ………………………………………………………… 68
Heading3 – ………………………………………………………… 69
Heading3 – Remove:………………………………………………….. 69
Heading2 – Remove Distributor………………………………………… 69
Heading3 – ………………………………………………………… 69
Heading3 – ………………………………………………………… 70
Heading3 – ………………………………………………………… 70
Heading3 – ………………………………………………………… 70
Heading3 – ………………………………………………………… 70
Heading3 – ………………………………………………………… 71
Heading3 – ………………………………………………………… 71
Heading3 – Clean:…………………………………………………… 71
Heading2 – Disassemble Intake Manifold (GXi only)………………………. 72
Heading3 – ………………………………………………………… 72
Heading3 – ………………………………………………………… 72
Heading3 – ………………………………………………………… 72
Heading3 – ………………………………………………………… 73
Heading3 – ………………………………………………………… 73
Heading3 – ………………………………………………………… 73
Heading3 – ………………………………………………………… 73
Heading3 – ………………………………………………………… 74
Heading3 – ………………………………………………………… 74
Heading3 – Clean and Inspect…………………………………………. 74
Heading3 – ………………………………………………………… 74
Heading2 – Assemble Intake Manifold…………………………………… 74
Heading3 – ………………………………………………………… 75
Heading3 – ………………………………………………………… 75
Heading3 – ………………………………………………………… 75
Heading2 – Intake Manifold Installation……………………………….. 75
Heading3 – Install or Connect:……………………………………….. 75
Heading3 – ………………………………………………………… 76
Heading3 – ………………………………………………………… 76
Heading3 – ………………………………………………………… 76
Heading3 – ………………………………………………………… 77
Heading3 – Tighten:…………………………………………………. 77
Heading2 – Distributor Installation…………………………………… 77
Heading3 – ………………………………………………………… 78
Heading3 – ………………………………………………………… 78
Heading3 – ………………………………………………………… 78
Heading3 – ………………………………………………………… 79
Heading3 – ………………………………………………………… 79
Heading3 – ………………………………………………………… 80
Heading3 – ………………………………………………………… 80
Heading3 – ………………………………………………………… 81
Heading3 – ………………………………………………………… 81
Heading3 – ………………………………………………………… 82
Heading3 – Alternator with mounting bracket……………………………. 82
Heading3 – Connect:…………………………………………………. 82
Heading1 – Rocker Arm Cover……………………………………………… 83
Heading3 – Remove:………………………………………………….. 83
Heading3 – ………………………………………………………… 83
Heading3 – ………………………………………………………… 83
Heading3 – Clean:…………………………………………………… 83
Heading3 – Inspect:…………………………………………………. 83
Heading3 – Installation……………………………………………… 83
Heading3 – Tighten:…………………………………………………. 84
Heading1 – Valve Train………………………………………………….. 84
Heading3 – Removal………………………………………………….. 84
Heading3 – ………………………………………………………… 84
Heading3 – ………………………………………………………… 84
Heading3 – ………………………………………………………… 84
Heading3 – ………………………………………………………… 85
Heading3 – ………………………………………………………… 85
Heading3 – Clean:…………………………………………………… 85
Heading3 – Inspect:…………………………………………………. 86
Heading3 – ………………………………………………………… 86
Heading3 – ………………………………………………………… 86
Heading2 – Valve Lifters and Guides Clean and Inspect…………………… 87
Heading3 – ………………………………………………………… 87
Heading2 – Valve Lifters…………………………………………….. 87
Heading3 – Installation……………………………………………… 87
Heading2 – Valve Lifter Installation………………………………….. 88
Heading2 – Valve Lifter Pushrod Guides………………………………… 88
Heading2 – Valve Push Rod……………………………………………. 88
Heading2 – Valve Rocker Arm Support…………………………………… 88
Heading2 – Rocker Arm……………………………………………….. 89
Heading2 – Install Rocker Arm Assemblies………………………………. 89
Heading2 – Tighten Rocker Arm Assemblies………………………………. 89
Heading2 – Valve Rocker Arm Cover Installation…………………………. 90
Heading3 – Tighten………………………………………………….. 90
Heading1 – Cylinder Head………………………………………………… 90
Heading3 – Removal………………………………………………….. 90
Heading3 – ………………………………………………………… 91
Heading3 – ………………………………………………………… 91
Heading3 – ………………………………………………………… 91
Heading3 – ………………………………………………………… 91
Heading2 – Cylinder Head Disassemble and Recondition……………………. 92
Heading3 – Disassemble:……………………………………………… 92
Heading3 – ………………………………………………………… 92
Heading2 – Cylinder Head Clean and Inspect…………………………….. 93
Heading3 – Clean:…………………………………………………… 93
Heading3 – Inspect:…………………………………………………. 93
Heading3 – Valve Spring Tension………………………………………. 94
Heading2 – Valve Spring Straightness………………………………….. 94
Heading2 – Valve Stems………………………………………………. 94
Heading3 – ………………………………………………………… 95
Heading2 – Valve Guide Reaming and Seat Grind ing………………………. 95
Heading3 – Measuring:……………………………………………….. 95
Heading3 – ………………………………………………………… 95
Heading3 – Reaming:…………………………………………………. 96
Heading3 – Inspect………………………………………………….. 96
Heading3 – ………………………………………………………… 96
Heading2 – Cylinder Head Assemble…………………………………….. 97
Heading2 – Install Oil Seal………………………………………….. 98
Heading3 – Install Valve Spring………………………………………. 99
Heading3 – ………………………………………………………… 99
Heading3 – Installation……………………………………………… 99
Heading3 – …………………………………………………………100
Heading3 – …………………………………………………………100
Heading3 – …………………………………………………………100
Heading3 – …………………………………………………………100
Heading3 – Tighten:………………………………………………….101
Heading3 – …………………………………………………………101
Heading1 – Oil Pan and OIl Pump…………………………………………..101
Heading3 – Removal…………………………………………………..101
Heading3 – …………………………………………………………102
Heading3 – …………………………………………………………102
Heading3 – …………………………………………………………102
Heading2 – Oil Pan Clean and Inspect…………………………………..103
Heading3 – …………………………………………………………103
Heading3 – …………………………………………………………103
Heading3 – Oil Pump Removal…………………………………………..103
Heading3 – …………………………………………………………104
Heading3 – …………………………………………………………104
Heading2 – Oil Pump Disassemble……………………………………….104
Heading3 – …………………………………………………………105
Heading3 – …………………………………………………………105
Heading3 – …………………………………………………………106
Heading3 – …………………………………………………………106
Heading3 – …………………………………………………………106
Heading2 – Oil Pump Clean and Inspect………………………………….106
Heading3 – Oil Pump Assemble………………………………………….107
Heading3 – …………………………………………………………107
Heading3 – …………………………………………………………108
Heading3 – …………………………………………………………108
Heading3 – …………………………………………………………108
Heading3 – Oil Pump Installation………………………………………108
Heading3 – …………………………………………………………109
Heading3 – …………………………………………………………109
Heading3 – Oil Pan Installation……………………………………….109
Heading3 – …………………………………………………………109
Heading3 – …………………………………………………………110
Heading3 – …………………………………………………………110
Heading3 – …………………………………………………………110
Heading3 – …………………………………………………………111
Heading3 – …………………………………………………………111
Heading1 – Water Pump……………………………………………………111
Heading3 – GXi………………………………………………………111
Heading3 – Removal…………………………………………………..111
Heading3 – …………………………………………………………112
Heading3 – …………………………………………………………112
Heading3 – Inspection………………………………………………..112
Heading3 – Installation………………………………………………112
Heading3 – …………………………………………………………112
Heading3 – …………………………………………………………113
Heading3 – GL……………………………………………………….113
Heading3 – Remove……………………………………………………113
Heading3 – …………………………………………………………113
Heading3 – …………………………………………………………113
Heading3 – …………………………………………………………114
Heading3 – …………………………………………………………114
Heading3 – …………………………………………………………114
Heading3 – …………………………………………………………114
Heading2 – Water Pump Installation…………………………………….115
Heading3 – …………………………………………………………115
Heading3 – …………………………………………………………115
Heading3 – …………………………………………………………115
Heading3 – …………………………………………………………116
Heading1 – Crankshaft Balancer……………………………………………116
Heading3 – Removal…………………………………………………..116
Heading3 – …………………………………………………………116
Heading3 – …………………………………………………………116
Heading3 – …………………………………………………………117
Heading3 – …………………………………………………………117
Heading2 – Crankshaft Balancer Inspect…………………………………117
Heading2 – Crankshaft Balancer Installation…………………………….117
Heading3 – …………………………………………………………118
Heading3 – …………………………………………………………118
Heading3 – …………………………………………………………118
Heading3 – …………………………………………………………119
Heading3 – …………………………………………………………119
Heading3 – …………………………………………………………119
Heading1 – Engine Front Cover…………………………………………….119
Heading3 – Removal…………………………………………………..120
Heading3 – …………………………………………………………120
Heading3 – …………………………………………………………120
Heading2 – Engine Front Cover Installa tion…………………………….121
Heading3 – …………………………………………………………121
Heading3 – …………………………………………………………121
Heading1 – Timing Chain and Sprocket………………………………………121
Heading3 – Removal…………………………………………………..121
Heading3 – …………………………………………………………122
Heading3 – …………………………………………………………122
Heading3 – …………………………………………………………122
Heading3 – …………………………………………………………123
Heading3 – …………………………………………………………123
Heading3 – …………………………………………………………123
Heading3 – Inspection………………………………………………..124
Heading3 – …………………………………………………………124
Heading3 – …………………………………………………………124
Heading3 – Installation………………………………………………125
Heading3 – …………………………………………………………125
Heading3 – …………………………………………………………125
Heading3 – …………………………………………………………126
Heading3 – …………………………………………………………126
Heading3 – …………………………………………………………126
Heading1 – Balance Shaft…………………………………………………127
Heading3 – Removal…………………………………………………..127
Heading3 – …………………………………………………………127
Heading3 – …………………………………………………………127
Heading3 – …………………………………………………………128
Heading3 – Clean and Inspect………………………………………….128
Heading3 – …………………………………………………………129
Heading2 – Balance Shaft Bearing or Bushing…………………………….129
Heading3 – Removal…………………………………………………..129
Heading3 – Balance Shaft Bearing or Bushing Installation…………………130
Heading3 – Balance Shaft Installation………………………………….130
Heading3 – …………………………………………………………131
Heading3 – …………………………………………………………131
Heading3 – …………………………………………………………131
Heading3 – …………………………………………………………132
Heading3 – …………………………………………………………132
Heading3 – …………………………………………………………132
Heading3 – …………………………………………………………133
Heading1 – Camshaft……………………………………………………..133
Heading3 – Remove……………………………………………………133
Heading3 – …………………………………………………………133
Heading3 – …………………………………………………………133
Heading3 – Inspect…………………………………………………..133
Heading3 – …………………………………………………………134
Heading3 – …………………………………………………………134
Heading3 – …………………………………………………………135
Heading3 – Installation………………………………………………135
Heading1 – Camshaft Bearings……………………………………………..136
Heading3 – Remove……………………………………………………136
Heading3 – …………………………………………………………136
Heading3 – …………………………………………………………137
Heading3 – Installation………………………………………………137
Heading3 – …………………………………………………………138
Heading3 – …………………………………………………………138
Heading3 – …………………………………………………………139
Heading1 – Piston, Connecting Rod, and Bearings…………………………….139
Heading3 – …………………………………………………………140
Heading3 – …………………………………………………………140
Heading3 – …………………………………………………………140
Heading3 – …………………………………………………………141
Heading2 – Piston and Connecting Rod Disas semble……………………….141
Heading3 – …………………………………………………………141
Heading3 – …………………………………………………………142
Heading2 – Clean and Inspect………………………………………….142
Heading3 – …………………………………………………………142
Heading3 – …………………………………………………………143
Heading3 – …………………………………………………………143
Heading3 – …………………………………………………………143
Heading3 – …………………………………………………………144
Heading3 – …………………………………………………………144
Heading3 – …………………………………………………………144
Heading3 – …………………………………………………………145
Heading3 – …………………………………………………………145
Heading2 – Piston Selection…………………………………………..145
Heading3 – …………………………………………………………146
Heading3 – …………………………………………………………146
Heading3 – Piston and Connecting Rod Assemble…………………………..146
Heading3 – …………………………………………………………147
Heading3 – …………………………………………………………147
Heading3 – Installation………………………………………………148
Heading3 – …………………………………………………………148
Heading3 – …………………………………………………………148
Heading3 – …………………………………………………………149
Heading3 – …………………………………………………………149
Heading3 – …………………………………………………………149
Heading3 – …………………………………………………………150
Heading1 – Engine Coupler………………………………………………..150
Heading3 – Removal…………………………………………………..150
Heading3 – …………………………………………………………150
Heading3 – …………………………………………………………150
Heading3 – …………………………………………………………151
Heading3 – …………………………………………………………151
Heading3 – …………………………………………………………151
Heading3 – Inspection………………………………………………..151
Heading3 – Installation………………………………………………152
Heading3 – …………………………………………………………152
Heading3 – …………………………………………………………152
Heading3 – …………………………………………………………152
Heading3 – …………………………………………………………153
Heading1 – Flywheel……………………………………………………..153
Heading3 – Removal…………………………………………………..153
Heading3 – …………………………………………………………153
Heading3 – …………………………………………………………153
Heading3 – Inspection………………………………………………..154
Heading3 – Installation………………………………………………154
Heading1 – Crankshaft Rear Oil Seal and Housing…………………………….154
Heading3 – Remove……………………………………………………154
Heading3 – …………………………………………………………154
Heading3 – …………………………………………………………155
Heading3 – …………………………………………………………155
Heading3 – …………………………………………………………155
Heading3 – Installation………………………………………………156
Heading3 – …………………………………………………………156
Heading3 – …………………………………………………………156
Heading3 – …………………………………………………………157
Heading1 – Crankshaft……………………………………………………158
Heading3 – Remove……………………………………………………158
Heading3 – …………………………………………………………158
Heading3 – …………………………………………………………158
Heading3 – …………………………………………………………159
Heading3 – …………………………………………………………159
Heading2 – Crankshaft and Bearings Clean and Inspect…………………….159
Heading3 – …………………………………………………………160
Heading3 – …………………………………………………………160
Heading3 – …………………………………………………………160
Heading3 – …………………………………………………………161
Heading3 – …………………………………………………………161
Heading3 – …………………………………………………………161
Heading3 – …………………………………………………………162
Heading3 – …………………………………………………………162
Heading3 – …………………………………………………………162
Heading3 – …………………………………………………………163
Heading2 – Measuring Crankshaft Bearing Clear ances……………………..163
Heading2 – Micrometer Method for Crankshaft Bearings…………………….163
Heading3 – …………………………………………………………164
Heading3 – …………………………………………………………164
Heading3 – Measuring Crankshaft Bearing Clearances (Plastic Gauge Method)….164
Heading3 – …………………………………………………………164
Heading3 – …………………………………………………………165
Heading3 – …………………………………………………………165
Heading3 – …………………………………………………………165
Heading3 – …………………………………………………………166
Heading3 – Crankshaft and Bearings Installation…………………………166
Heading3 – …………………………………………………………166
Heading3 – …………………………………………………………167
Heading3 – …………………………………………………………167
Heading3 – …………………………………………………………167
Heading1 – Recondition Engine Block……………………………………….168
Heading2 – Engine Block Plug………………………………………….168
Heading3 – Removal…………………………………………………..168
Heading3 – …………………………………………………………168
Heading3 – …………………………………………………………169
Heading3 – …………………………………………………………169
Heading3 – …………………………………………………………169
Heading3 – …………………………………………………………170
Heading3 – …………………………………………………………170
Heading3 – …………………………………………………………170
Heading3 – …………………………………………………………171
Heading2 – Engine Block Clean and inspect………………………………171
Heading3 – …………………………………………………………172
Heading2 – Cylinder Boring and Honing………………………………….172
Heading3 – Honing Procedure…………………………………………..172
Heading2 – Boring Procedure…………………………………………..173
Heading1 – Remove and Install Engine………………………………………174
Heading1 – Engine Specifications………………………………………….174
ChapterTitle – Section 4: Steering System……………………………………..181
Heading2 – Special Tools…………………………………………………181
Heading3 – Kent-Moore Special Tools……………………………………….181
Heading3 – Sealants, Lubricants and Adhesives………………………………182
Heading1 – Power Steering System………………………………………….182
Heading2 – Description……………………………………………….182
Heading3 – …………………………………………………………183
Heading1 – Pump Operation………………………………………………..183
Heading3 – …………………………………………………………183
Heading1 – System Operation………………………………………………184
Heading3 – No Steering Input – Steering Wheel Not Turning………………..184
Heading3 – Steering To Port – Steering Wheel Turning To Left……………..184
Heading3 – Steering To Starboard – Steering Wheel Turning To Right………..185
Heading3 – Steering Without Power Assist……………………………….185
Heading1 – Pump Removal………………………………………………….185
Heading3 – …………………………………………………………185
Heading3 – Serpentine Belt Models Only…………………………………186
Heading3 – …………………………………………………………186
Heading3 – …………………………………………………………186
Heading3 – …………………………………………………………186
Heading3 – V-Belt Models Only…………………………………………187
Heading3 – …………………………………………………………187
Heading3 – …………………………………………………………187
Heading1 – Pump Installation……………………………………………..187
Heading3 – …………………………………………………………187
Heading3 – …………………………………………………………188
Heading3 – Serpentine Belt Models Only…………………………………188
Heading3 – …………………………………………………………188
Heading3 – V-Belt Models Only…………………………………………188
Heading1 – Hydraulic Fluid……………………………………………….188
Heading2 – Checking Fluid Level……………………………………….188
Heading1 – Purging Air From Steering System………………………………..189
Heading1 – Power Steering Pump Belt Adjustment……………………………..189
Heading3 – Serpentine Belt Models……………………………………..189
Heading3 – V- Belt Models…………………………………………….190
Heading3 – …………………………………………………………190
Heading3 – …………………………………………………………190
Heading1 – Steering Cylinder……………………………………………..190
Heading3 – …………………………………………………………190
Heading1 – Cylinder Removal………………………………………………191
Heading3 – …………………………………………………………191
Heading3 – …………………………………………………………191
Heading3 – …………………………………………………………191
Heading3 – …………………………………………………………191
Heading3 – …………………………………………………………191
Heading3 – …………………………………………………………192
Heading1 – Cylinder Servicing…………………………………………….192
Heading3 – …………………………………………………………192
Heading3 – …………………………………………………………192
Heading1 – Cylinder Installation………………………………………….193
Heading3 – …………………………………………………………193
Heading3 – …………………………………………………………193
Heading3 – …………………………………………………………193
Heading3 – …………………………………………………………193
Heading3 – …………………………………………………………194
Heading1 – Cable Installation…………………………………………….194
Heading3 – …………………………………………………………194
Heading3 – …………………………………………………………194
Heading3 – …………………………………………………………194
Heading3 – …………………………………………………………195
Heading3 – …………………………………………………………195
Heading3 – …………………………………………………………195
Heading1 – Lubrication…………………………………………………..195
Heading3 – …………………………………………………………195
Heading1 – Hoses………………………………………………………..196
Heading1 – System Diagnosis………………………………………………196
Heading2 – System Checks……………………………………………..196
Heading1 – Tie Bar Adjustment – Twin Engine Installation…………………….196
Heading3 – …………………………………………………………196
Heading3 – …………………………………………………………197
Heading2 – Power Steering System Diagnosis Chart………………………..197
Heading1 – External Leakage………………………………………………198
Heading2 – General Procedure………………………………………….198
Heading2 – Leakage Checks…………………………………………….198
Heading2 – Easily Fixed Leaks…………………………………………198
Heading1 – Pump Leakage………………………………………………….199
Heading3 – …………………………………………………………199
Heading2 – Pump Pressure Test…………………………………………199
Heading3 – …………………………………………………………199
Heading1 – Cable Installation Problems…………………………………….200
Heading3 – …………………………………………………………200
Heading3 – …………………………………………………………200
Heading3 – …………………………………………………………200
Heading3 – …………………………………………………………201
Heading1 – Feedback To The Helm…………………………………………..201
ChapterTitle – Section 5: Throttle & Shift Control System……………………….203
Heading1 – Installation of Shift and Throttle Cables………………………..203
Heading3 – …………………………………………………………203
Heading2 – Check Remote Control Shift Cable Stroke………………………204
Heading3 – …………………………………………………………204
Heading3 – …………………………………………………………204
Heading3 – …………………………………………………………204
Heading3 – …………………………………………………………204
Heading2 – Installation of SAE Cables to Engine/ Drive…………………..204
Heading3 – Shift Cable to Sterndrive…………………………………..205
Heading3 – …………………………………………………………205
Heading3 – …………………………………………………………205
Heading3 – …………………………………………………………205
Heading3 – …………………………………………………………205
Heading3 – …………………………………………………………206
Heading3 – …………………………………………………………206
Heading3 – …………………………………………………………206
Heading3 – …………………………………………………………206
Heading3 – …………………………………………………………207
Heading3 – …………………………………………………………207
Heading2 – Throttle Cable to Engine……………………………………207
Heading3 – …………………………………………………………207
Heading3 – …………………………………………………………208
Heading3 – …………………………………………………………208
Heading3 – …………………………………………………………208
Heading3 – …………………………………………………………208
Heading3 – …………………………………………………………208
Heading1 – Neutral Start Switch Tests……………………………………..209
Heading2 – Electrical………………………………………………..209
Heading2 – Mechanical………………………………………………..209
Heading1 – Removal of SAE Remote Control Cables…………………………….209
Heading2 – Throttle Cable From Engine………………………………….210
Heading3 – …………………………………………………………210
Heading2 – Shift Cable From Sterndrive…………………………………210
Heading3 – …………………………………………………………210
Heading3 – …………………………………………………………210
Heading3 – …………………………………………………………210
Heading3 – …………………………………………………………210
ChapterTitle – Section 6: Cooling System………………………………………211
Heading1 – Description…………………………………………………..211
Heading2 – Raw Water Cooled Engines……………………………………211
Heading3 – …………………………………………………………212
Heading2 – Closed Cooling Engines……………………………………..213
Heading1 – Cooling System Troubleshooting………………………………….214
Heading3 – Quiz Customer for the Following Information:………………….214
Heading3 – Possibilities To Consider:………………………………….214
Heading2 – Isolating Cooling Problem:………………………………….215
Heading3 – Air or exhaust gas entering cooling water:……………………215
Heading3 – Insufficient water supply:………………………………….215
Heading3 – Thermostat malfunction……………………………………..215
Heading3 – Engine head gasket leakage………………………………….215
Heading1 – Cooling System Components………………………………………216
Heading2 – Hoses, Clamps, and Drain Plugs………………………………216
Heading2 – Thermostat………………………………………………..216
Heading3 – …………………………………………………………216
Heading2 – Manifolds and Elbows……………………………………….216
Heading2 – Circulating Pump – Engine…………………………………..216
Heading2 – Supply Pump……………………………………………….217
Heading3 – …………………………………………………………217
Heading3 – …………………………………………………………217
Heading2 – Impeller Removal…………………………………………..217
Heading3 – …………………………………………………………218
Heading3 – …………………………………………………………218
Heading3 – …………………………………………………………218
Heading3 – Cleaning and Inspection…………………………………….218
Heading2 – Impeller Installation………………………………………219
Heading3 – …………………………………………………………219
Heading3 – …………………………………………………………219
Heading3 – …………………………………………………………219
Heading1 – Draining Engine Block or Exhaust Manifold………………………..220
Heading2 – 4.3GXi-A/B………………………………………………..220
Heading3 – …………………………………………………………220
Heading2 – 4.3GXi, 4.3OSi F-series (closed cooling)……………………..221
Heading2 – 4.3GXi-C/D………………………………………………..221
Heading2 – 4.3GXi-A, and 4.3GL Draining Only……………………………222
Heading3 – …………………………………………………………222
Heading2 – Draining Supply Pump……………………………………….222
Heading3 – …………………………………………………………222
Heading2 – Thermostat Replacement……………………………………..223
Heading3 – …………………………………………………………223
Heading3 – …………………………………………………………223
Heading3 – …………………………………………………………223
Heading3 – Numbers refer to Cooling System Flow Diagrams…………………224
Heading1 – Sterndrive and Transom Bracket Cooling Schematic………………….225
Heading1 – 4.3GL-A/B/C/D Engine Cooling Diagram…………………………….226
Heading1 – 4.3GXi-A Engine Cooling Diagram…………………………………227
Heading1 – 4.3GXi-B/C/D/E Cooling Diagram………………………………….228
Heading1 – 4.3GXi-BF/CF/DF/EF Engine Cooling Diagram………………………..229
ChapterTitle – Section 7: Engine Removal and Installation……………………….231
Heading2 – Special Tools…………………………………………………231
Heading2 – Sealants, Lubricants and Adhesives………………………………231
Heading1 – Engine Removal………………………………………………..231
Heading3 – Disconnect Battery…………………………………………232
Heading3 – Disconnect Power Steering Lines……………………………..232
Heading3 – …………………………………………………………232
Heading3 – Disconnect Fuel Supply……………………………………..232
Heading3 – …………………………………………………………232
Heading3 – Disconnect Electrical Cables………………………………..233
Heading3 – …………………………………………………………233
Heading3 – …………………………………………………………233
Heading3 – …………………………………………………………233
Heading3 – Disconnect Throttle Cable…………………………………..234
Heading3 – …………………………………………………………234
Heading3 – Disconnect Exhaust Hose…………………………………….234
Heading3 – …………………………………………………………234
Heading3 – Disconnect Water Hose………………………………………234
Heading3 – …………………………………………………………234
Heading3 – Separate Engine Mounts……………………………………..235
Heading3 – …………………………………………………………235
Heading3 – …………………………………………………………235
Heading3 – …………………………………………………………235
Heading2 – Exhaust Pipe Replacement……………………………………235
Heading3 – Removal…………………………………………………..235
Heading3 – …………………………………………………………236
Heading3 – Installation………………………………………………236
Heading3 – …………………………………………………………236
Heading3 – …………………………………………………………236
Heading2 – Engine Installation………………………………………..236
Heading3 – Attach Engine Mount………………………………………..236
Heading3 – …………………………………………………………237
Heading3 – …………………………………………………………237
Heading2 – Engine Alignment…………………………………………..237
Heading3 – …………………………………………………………237
Heading3 – …………………………………………………………238
Heading2 – Connect Exhaust Hose……………………………………….238
Heading3 – …………………………………………………………238
Heading3 – …………………………………………………………238
Heading2 – Connect Throttle Cable……………………………………..238
Heading3 – …………………………………………………………238
Heading3 – Carbureted Models Only……………………………………..239
Heading3 – …………………………………………………………239
Heading3 – …………………………………………………………239
Heading3 – …………………………………………………………239
Heading3 – …………………………………………………………239
Heading3 – Connect Water Hose…………………………………………240
Heading3 – …………………………………………………………240
Heading3 – …………………………………………………………240
Heading3 – Connect Power Steering Lines………………………………..240
Heading3 – …………………………………………………………240
Heading3 – …………………………………………………………241
Heading3 – …………………………………………………………241
Heading3 – …………………………………………………………241
Heading3 – …………………………………………………………241
Heading3 – Connect Electrical Cables…………………………………..242
Heading3 – …………………………………………………………242
Heading3 – …………………………………………………………242
Heading3 – …………………………………………………………243
Heading2 – Connect Fuel Supply………………………………………..243
Heading3 – …………………………………………………………243
Heading1 – Rear Engine Mounts…………………………………………….243
Heading3 – Removal…………………………………………………..243
Heading3 – …………………………………………………………244
Heading3 – Disassembly……………………………………………….244
Heading3 – …………………………………………………………244
Heading3 – Assembly………………………………………………….244
Heading3 – …………………………………………………………244
Heading3 – Installation………………………………………………245
Heading3 – …………………………………………………………245
Heading3 – …………………………………………………………245
Heading1 – Determining Minimum Engine Height……………………………….246
Heading3 – …………………………………………………………246

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