Volvo Penta 5.0GL-ABCDE- 5.7GXI-A B C D F Engine Workshop Manual_81843740 – PDF DOWNLOAD

Volvo Penta 5.0GL-ABCDE- 5.7GXI-A B C D F Engine Workshop Manual_81843740 – PDF DOWNLOAD

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Volvo Penta 5.0GL-ABCDE- 5.7GXI-A B C D F Engine Workshop Manual_81843740 – PDF DOWNLOAD

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Volvo Penta 5.0GL-ABCDE- 5.7GXI-A B C D F Engine Workshop Manual_81843740 – PDF DOWNLOAD

5.0GL-A/ Bl Cl 0] E 5.7GXi-A/B/C(F)/D(F)/E(F)/F(F)5.0GXi-A/B(F)lC(F)/D(F)/ E(F) 5.7OSi-A(F)/B(F)lC(F)/D(F)IE(F)5.00OSi-B(F)/C(F)lD(F)/E(F) 5.7OSXi-A(F)/B(F)/C(F)/D(F)/E(F)5.7GL-A/B/C/D/E 5.7GiI-A/B/C/D/ F5.7Gi-A/B(F)/C(F)/D(F)/E(F) 5.7GXi-A/ B/ C/ D/ FGood 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 5.0GL-ABCDE- 5.7GXI-A B C D F Engine Workshop Manual_81843740 – PDF DOWNLOAD

Model Identification………………………………………………………………………………………………………….. 4
Engine Model Number…………………………………………………………………………………………………………… 4
Emission Control Labels……………………………………………………………………………………………………….. 5
Transom Shield Model Number Location……………………………………………………………………………………………. 6
Sterndrive Model Number Location……………………………………………………………………………………………….. 6
Section 1: General Information…………………………………………………………………………………………………. 7
Tuning the Engine…………………………………………………………………………………………………………. 9
Engine Compression Testing……………………………………………………………………………………………… 10
Test Conclusion……………………………………………………………………………………………………….. 10
Ignition System Components……………………………………………………………………………………………… 11
Fuel System Components…………………………………………………………………………………………………. 11
Intake Manifold Vacuum Testing………………………………………………………………………………………….. 12
Gasoline Requirements………………………………………………………………………………………………….. 14
Gasoline Containing Alcohol…………………………………………………………………………………………….. 14
Crankcase Oil…………………………………………………………………………………………………………….. 15
Steering System Lubrication………………………………………………………………………………………………… 16
Power Trim/Tilt Fluid Level………………………………………………………………………………………………… 17
Off-Season Storage………………………………………………………………………………………………………… 17
Preparation for Boating After Storage……………………………………………………………………………………….. 19
Engine Break-in…………………………………………………………………………………………………………… 20
Submerged Engine………………………………………………………………………………………………………….. 22
20-Hour Check…………………………………………………………………………………………………………….. 22
Belt Tension……………………………………………………………………………………………………………… 23
Alternator Belt Adjustment……………………………………………………………………………………………… 23
Power Steering Pump Belt Adjustment……………………………………………………………………………………… 23
Positive Closed-Type Ventilation System……………………………………………………………………………………… 24
Troubleshooting – System Isolation………………………………………………………………………………………….. 25
Engine Troubleshooting Guides………………………………………………………………………………………………. 25
Engine Will Not Crank………………………………………………………………………………………………….. 27
Engine Cranks, But Will Not Start……………………………………………………………………………………….. 27
Hard Starting – Cold Engine…………………………………………………………………………………………….. 28
Hard Starting – Hot Engine……………………………………………………………………………………………… 28
Engine Runs Rough……………………………………………………………………………………………………… 28
Engine Noises and Vibrations……………………………………………………………………………………………. 29
Engine Overheats – Check:………………………………………………………………………………………………. 30
Engine Dies Out……………………………………………………………………………………………………….. 30
Engine Won’t Reach Operating RPM – Check:………………………………………………………………………………… 31
Defective Engine Lubricating System……………………………………………………………………………………… 31
Low Battery Voltage After Short Storage………………………………………………………………………………….. 31
Section 2: General Mechanical………………………………………………………………………………………………….. 33
General Description……………………………………………………………………………………………………….. 33
Cleanliness and Care………………………………………………………………………………………………………. 34
Use of RTV Sealer and Anaerobic Gasket Eliminator…………………………………………………………………………….. 34
Replacing Engine Gaskets…………………………………………………………………………………………………… 35
Cylinder Bores……………………………………………………………………………………………………………. 36
Piston and Connecting Rod………………………………………………………………………………………………….. 39
Measuring Piston Pin to Piston Clearance…………………………………………………………………………………….. 40
Piston Selection………………………………………………………………………………………………………….. 41
Assembling the Piston and Connecting Rod…………………………………………………………………………………….. 41
Installing the Piston Rings………………………………………………………………………………………………… 42
Camshaft Bearings…………………………………………………………………………………………………………. 44
Camshaft Bearing Removal……………………………………………………………………………………………….. 44
Camshaft Measurements………………………………………………………………………………………………….. 44
Cylinder Head…………………………………………………………………………………………………………….. 46
Valve Grinding………………………………………………………………………………………………………… 48
Valves and components………………………………………………………………………………………………….. 49
Crankshaft and Connecting Rod Bearings………………………………………………………………………………………. 49
Thread Repair…………………………………………………………………………………………………………….. 52
Special Tools…………………………………………………………………………………………………………….. 54
Section 3: Engine – 5.0 & 5.7 Liter…………………………………………………………………………………………….. 57
General Description……………………………………………………………………………………………………….. 58
Tools and Shop Equipment…………………………………………………………………………………………………… 59
Accessories………………………………………………………………………………………………………………. 59
Cleaning…………………………………………………………………………………………………………………. 60
Draining The Engine……………………………………………………………………………………………………….. 60
Engine Lubrication………………………………………………………………………………………………………… 60
Exhaust Manifold………………………………………………………………………………………………………….. 61
Starter………………………………………………………………………………………………………………….. 63
Intake Manifold…………………………………………………………………………………………………………… 64
Remove Distributor, Gi and GXi Models……………………………………………………………………………………. 66
Disassemble Intake Manifold (GXi-B and later only)………………………………………………………………………… 68
Assemble Intake Manifold……………………………………………………………………………………………….. 71
Intake Manifold Installation……………………………………………………………………………………………. 72
Distributor Installation……………………………………………………………………………………………….. 73
Rocker Arm Cover………………………………………………………………………………………………………….. 78
Valve Train………………………………………………………………………………………………………………. 78
Valve Lifters and Guides Clean and Inspect……………………………………………………………………………….. 81
Valve Lifter Installation………………………………………………………………………………………………. 82
Valve Lifter Pushrod Guides…………………………………………………………………………………………….. 83
Valve Push Rod………………………………………………………………………………………………………… 83
Install Rocker Arm Assemblies…………………………………………………………………………………………… 83
Valve Lash Adjustment………………………………………………………………………………………………….. 84
Valve Rocker Arm Cover Installation……………………………………………………………………………………… 85
Cylinder Head…………………………………………………………………………………………………………….. 85
Cylinder Head Disassemble and Recondition………………………………………………………………………………… 87
Cylinder Head Clean and Inspect…………………………………………………………………………………………. 88
Valve Spring Straightness………………………………………………………………………………………………. 89
Valve Stems…………………………………………………………………………………………………………… 89
Valve Guide Reaming and Seat Grinding……………………………………………………………………………………. 90
Valve Rocker Arm Stud Removal…………………………………………………………………………………………… 92
Valve Rocker Arm Stud Installation………………………………………………………………………………………. 92
Cylinder Head Assemble…………………………………………………………………………………………………. 93
Install Oil Seal………………………………………………………………………………………………………. 93
Oil Pan and OIl Pump………………………………………………………………………………………………………. 97
Oil Pan Clean and Inspect………………………………………………………………………………………………. 98
Oil Pump Disassemble……………………………………………………………………………………………………100
Oil Pump Clean and Inspect………………………………………………………………………………………………101
Water Pump………………………………………………………………………………………………………………..106
Water Pump Installation…………………………………………………………………………………………………109
Crankshaft Balancer………………………………………………………………………………………………………..111
Crankshaft Balancer Inspect……………………………………………………………………………………………..112
Crankshaft Balancer Installation…………………………………………………………………………………………112
Engine Front Cover…………………………………………………………………………………………………………114
Engine Front Cover Installation………………………………………………………………………………………….115
Timing Chain and Sprocket……………………………………………………………………………………………….116
Camshaft………………………………………………………………………………………………………………120
Camshaft Bearings………………………………………………………………………………………………………….123
Piston, Connecting Rod, and Bearings…………………………………………………………………………………………127
Piston and Connecting Rod Disassemble…………………………………………………………………………………….129
Clean and Inspect………………………………………………………………………………………………………130
Piston Selection……………………………………………………………………………………………………….133
Engine Coupler…………………………………………………………………………………………………………….138
Flywheel………………………………………………………………………………………………………………….141
Crankshaft Rear Oil Seal and Housing…………………………………………………………………………………………142
Crankshaft………………………………………………………………………………………………………………..145
Crankshaft and Bearings Clean and Inspect…………………………………………………………………………………147
Measuring Crankshaft Bearing Clearances…………………………………………………………………………………..150
Micrometer Method for Crankshaft Bearings…………………………………………………………………………………150
Recondition Engine Block……………………………………………………………………………………………………155
Engine Block Plug………………………………………………………………………………………………………155
Engine Block Clean and inspect…………………………………………………………………………………………..158
Cylinder Boring and Honing………………………………………………………………………………………………159
Boring Procedure……………………………………………………………………………………………………….160
Engine Specifications………………………………………………………………………………………………………161
Tune Up Specifications……………………………………………………………………………………………………..167
Section 4: Steering System……………………………………………………………………………………………………..169
Special Tools……………………………………………………………………………………………………………..169
Volvo Penta Special Tools……………………………………………………………………………………………….169
Kent-Moore Special Tools………………………………………………………………………………………………..169
Power Steering System………………………………………………………………………………………………………170
Description……………………………………………………………………………………………………………170
Pump Operation…………………………………………………………………………………………………………….171
System Operation…………………………………………………………………………………………………………..172
Pump Removal………………………………………………………………………………………………………………173
Pump Installation………………………………………………………………………………………………………….175
Hydraulic Fluid……………………………………………………………………………………………………………176
Checking Fluid Level……………………………………………………………………………………………………176
Purging Air From Steering System…………………………………………………………………………………………….177
Power Steering Pump Belt Adjustment………………………………………………………………………………………….177
Steering Cylinder………………………………………………………………………………………………………….178
Cylinder Removal…………………………………………………………………………………………………………..179
Cylinder Servicing…………………………………………………………………………………………………………180
Cylinder Installation………………………………………………………………………………………………………181
Cable Installation…………………………………………………………………………………………………………182
Lubrication……………………………………………………………………………………………………………….183
Hoses…………………………………………………………………………………………………………………….184
System Diagnosis…………………………………………………………………………………………………………..184
System Checks………………………………………………………………………………………………………….184
Tie Bar Adjustment – Twin Engine Installation…………………………………………………………………………………184
Power Steering System Diagnosis Chart…………………………………………………………………………………….185
External Leakage…………………………………………………………………………………………………………..186
General Procedure………………………………………………………………………………………………………186
Leakage Checks…………………………………………………………………………………………………………186
Easily Fixed Leaks……………………………………………………………………………………………………..186
Pump Leakage………………………………………………………………………………………………………………187
Pump Pressure Test……………………………………………………………………………………………………..187
Cable Installation Problems…………………………………………………………………………………………………188
Feedback To The Helm……………………………………………………………………………………………………….189
Section 5: Throttle & Shift Control System……………………………………………………………………………………….191
Installation of Shift and Throttle Cables…………………………………………………………………………………….191
Check Remote Control Shift Cable Stroke…………………………………………………………………………………..192
Installation of SAE Cables to Engine/ Drive……………………………………………………………………………….192
Throttle Cable to Engine………………………………………………………………………………………………..195
Neutral Start Switch Tests………………………………………………………………………………………………….197
Electrical…………………………………………………………………………………………………………….197
Mechanical…………………………………………………………………………………………………………….197
Removal of SAE Remote Control Cables…………………………………………………………………………………………197
Throttle Cable From Engine………………………………………………………………………………………………198
Shift Cable From Sterndrive……………………………………………………………………………………………..198
Section 6: Cooling System………………………………………………………………………………………………………199
Description……………………………………………………………………………………………………………….199
Raw Water Cooled Engines………………………………………………………………………………………………..199
Closed Cooling Engines………………………………………………………………………………………………….201
Cooling System Troubleshooting………………………………………………………………………………………………202
Isolating Cooling Problem:………………………………………………………………………………………………203
Cooling System Components…………………………………………………………………………………………………..204
Hoses, Clamps, and Drain Plugs…………………………………………………………………………………………..204
Thermostat…………………………………………………………………………………………………………….204
Manifolds and Elbows……………………………………………………………………………………………………204
Circulating Pump – Engine……………………………………………………………………………………………….204
Supply Pump……………………………………………………………………………………………………………205
Impeller Removal……………………………………………………………………………………………………….205
Impeller Installation…………………………………………………………………………………………………..207
Draining Engine Block or Exhaust Manifold…………………………………………………………………………………….208
Draining Supply Pump……………………………………………………………………………………………………210
Thermostat Replacement………………………………………………………………………………………………….210
Sterndrive and Transom Bracket Cooling Schematic………………………………………………………………………………213
5.0/5.7GL Engine Cooling Diagram…………………………………………………………………………………………….214
5.0GXi-A, 5.7Gi-A, 5.7GXi-A/B Cooling Diagram…………………………………………………………………………………215
5.0GXi-B/C/D/E, 5.0OSi-B/C/D/E, 5.7Gi-B/C/D/E, 5.7OSi-A/B/C/D, 5.7GXi-C/D/E/ F, 5.7OSXi-A/B/C/D Cooling Diagram………………………216
5.0GXi-BF/CF/DF/EF, 5.0OSi BF/CF/DF/EF, 5.7Gi-BF/CF/DF/EF, 5.7OSi-AF/BF/ CF/DF, 5.7GXi-CF/DF/EF/FF 5.7OSXi-AF/BF/CF/DF Cooling Diagram….217
Section 7: Engine Removal and Installation……………………………………………………………………………………….219
Special Tools……………………………………………………………………………………………………………..219
Sealants, Lubricants and Adhesives…………………………………………………………………………………………..219
Engine Removal…………………………………………………………………………………………………………….219
Exhaust Pipe Replacement………………………………………………………………………………………………..223
Engine Installation…………………………………………………………………………………………………….224
Engine Alignment……………………………………………………………………………………………………….225
Connect Exhaust Hose……………………………………………………………………………………………………226
Connect Throttle Cable………………………………………………………………………………………………….226
Connect Fuel Supply…………………………………………………………………………………………………….231
Rear Engine Mounts…………………………………………………………………………………………………………231
Determining Minimum Engine Height……………………………………………………………………………………………233