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Z~ Safety Warning This Workshop Manual will alert you to certain procedures that 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 people around the boat ® Damage the Volvo Penta product or its systems Understand the following symbols before proceeding: Alerts you to the possibility of danger andZ~ Safety Warning identifies information that will help prevent injuries. identifies information that will help prevent damage to machinery. Appears next to information that controls correct assembly and operation of the product. This Workshop Manual is written for qualified, factory trained service technicians familiar with the use of Volvo Penta special tools. This Workshop ManuaB tells you how to correctly maintain and service Volvo Penta products and systems. When correctly serviced, the Volvo Penta product will be reliable and safe to operate. When VoUvo Penta special tools are called for, use them. Where mentioned, the tools are required to perform the service procedure. if you use service procedures or service tools that are not recommendedin this manual, YOU ALONE must decide if your actions might injure people or damage the Volvo Penta product. Contents General information .............................. Carbureted Fuel System ............................ 7.4Gi MFi System ................................. 7..4GSi and 8.2GSi MFi System ...................... 4.3Gi, 5.0Gi, and 5. 7GSiTBiSystem ................. Safety Section .................................... This workshop manualis one of a set of four that covers Volvo Penta stern- drive "BY" models. All four books can be ordered as a set from Volvo Penta Parts. Order P/N 7797450-9. Individual workshop manualscovering these models are also available. Order the following part numbers fromVolvo Penta Parts. ¯P/N 7797451-7 Engine Components includes information on Engine service and troubleshooting; Engine removal and installation; Steering systems; Throttle and Shift Control systems; and Cooling systems. ¯ P/N 7797452-5 Electrical & Ignition System Includes service and troubleshooting information on Cranking systems; Chargingsystems; Trim/Tilt electrical systems; Ignition systems; and Engine and Instrument wiring diagrams. ,P/N 7797453-3 Fuel System Includes service and troubleshooting information on all carburetor, MFI and TBI fuel systems and related components. ¯P/N 7797454-1 EF! Diagnostic Manual GM Contains troubleshooting procedures for all Electronic Fuel injected GM models and related components. ¯ P/N 7797455-8 SX and DP-S Sterndrives and Transom Shield Includes information on Transom Shield, Upper Gear Unit and Lower Gear Unit service; Drive Unit removal and installation; Propellers; and Trim/Tilt hydraulic operation. Engine 3.0 GS 4.3 GL 4.3 GS 4.3 Gi 5.0 GL This Volvo Penta Workshop iis part of a set that Manual covers the following Volvo Penta "BY" Models Steering Model Number Transom Shield Drive Unit Manual 30GSMBYCCE 3868844, 3868895 (1.97:1) SX-M Manual 30GSMBYCCE 3868844 3868896 (2.18:1) SX-M Manual 30GSMBYCCE 3868845 3868895 (1.97:1) SX-M Manual 30GSMBYCCE 3868845 3868896 (2.18:1) SX-M Power 30GSPBYCCE 3868844 3868895 (1.97:1) SX-M Power 30GSPBYCCE 3868844 3868896 (2.18:1) SX-M Power 30GSPBYCCE 3868845 3868895 (1.97:1) SX-M Power 30GSPBYCCE 3868845 3868896 (2.t8:1) SX-M Power 43GLPBYC 3868844 3868892 (1.66:1) SX-M Power 43GLPBYC 3868844 3868893 (1.79:1) SX-M Power 43GLPBYC 3868844 3868894 (1.89:1) SX-M Power 43GLPBYC 3868844 3868913 (1.95:1) DP-SM Power 43GLPBYC 3868844 3868914 (2.32:1) DP-SM Power 43GLPBYC 3868846 3868892 (1.66:1) SX-M Power 43GLPBYC 3868846 3868893 (1.79:1) SX-M Power 43GLPBYC 3868846 3868894 (1.89:1) SX-M Power 43GLPBYC 3868846 3868913 (1.95:1) DP-SM Power 43GLPBYC 3868846 3868914 (2.32:1) DP-SM Power 43GSJBYA 3868694 PJX-C1 Power 43GSPBYC 3868844 3868892 (1.66:1) SX-M Power 43GSPBYC 3868844 3868893 (1.79:1) SX-M Power 43GSPBYC 3868844 3868913 (1.95:1) DP-SM Power 43GSPBYC 3868844 3868914 (2.32:1) DP-SM Power 43GSPBYC 3868846 3868892 {1.66:1) SX-M Power 43GSPBYC 3868846 3868893 (1.79:1} SX=M Power 43GSPBYC 3868846 3868913 {1.95:1) DP-SM Power 43GSPBYC 3868846 3868914 (2.32:1) DP-SM Power 43GIJBYA m 3868694 PJX-C1 Power 43GIPBYCCE 3868844 3868892 (1.66:1) SX-M Power 43GIPBYCCE 3868844 3868893 (1.79:1) SX-M Power 43GIPBYCCE 3868844 3868913 (1.95:1) DP-SM Power 43GIPBYCCE 3868844 3868914 (2.32:1) DP-SM Power 43GIPBYCCE 3868846 3868892 (1.66:1) SX-M Power 43GIPBYCCE 3868846 3868893 (1.79:1) SX-M Power 43GIPBYCCE 3868846 3868913 (1.95:1) DP-SM Power 43GIPBYCCE 3868846 3868914 (2.32:1) DP-SM Power 50GLPBYC 3868844 3868891 (1.60:1) SX-M Power 50GLPBYC 3868844 3868890 (1.51:l)SX-M Power 50GLPBYC 3868844 3868912 (1.78:1) DP-SM Power 50GLPBYC 3868844 3868913 (1.95:1) DP-SM Power 50GLPBYC 3868846 3868891 (1.60:1) SX-M Power 50GLPBYC 3868846 3868890 (1.51:1) SX-M Power 50GLPBYC 3868846 3868912 (1.78:1) DP-SM Power 50GLPBYC 3868846 3868913 (1.95:1) DP-SM This Volvo Penta Workshop is part of a set that Manual covers the following Volvo Penta "BY" Models Engine 5.0 Gi 5.7 GS 5.7 GSi 7.4 Gi 7.4 GSi 8.2 GSi DPX 385 DPX 415 Steering Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Xact Xact Xact Xact Xact Xact Model Number 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPSYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GSmPBYCCE 74GSIPBYCCE 74GSIPBYCCE 74GSIPBYCCE 82GSIPBYCCE 82GSIPSYOCE 82GSIPBYCCE 82GSIPBYCCE DPX385XBYDCE DPX385XBYDCE DPX385XBYDCE DPX415XBYDCE DPX415XBYDCE DPX415XBYDCE Transom Shield Drive Unit 3868844 3868891 (1.60:1) SX-M 3868844 3868890 (1.51:1) SX-M 3868844 3868912 (1.78:1) DP-SM 3868844 3888913 (1.95:1) DP-SM 3868846 3868891 (1.60:1) SX-M 3868846 3868890 (1.51:1) SX-M 3868846 3868912 (1.78:1) DP-SM 3868846 3868913 (1.95:1) DP-SM 3868844 3868889 (1.43:1) SX-M 3868844 3868890 (1.51:1)SX-M 3868844 3868912 (1.78:1) DP-SM 3868844 3868913 (1.95:1) DP-SM 3868846 3868889 (1.43:1) SX-M 3868846 3868890 (1.51:1) SX-M 3868846 3868912 (1.78:1) DP-SM 3868846 3868913 (1.95:1) DP-SM 3868844 3868889 (1.43:1) SX-M 3868844 3868912 (1.78:1) DP-SM 3868844 3868913 (1.95:11 DP-SM 3868846 3868889 (1.43:1) SX-M 3868848 3868912 (1.78:1) DP-SM 3868846 3868913 (1.95:1) DP-SM 3868844 3868889 (1.43:1) SX-M 3868844 3868911 (1.68:1) DP-SM 3868844 3868912 (1.78:1) DP-SM 3868844 3868913 (1.95:1) DP-SM 3868846 3888889 (1.43:1) SX-M 3868846 3888911 (1.68:1) DP-SM 3868846 3868912 (1.78:1) DP-SM 3868846 3868913 (1.95:1) DP-SM 3868850 3888911 (1.68:l)DP-SM 3868850 3868912 (1.78:1) DP-SM 3868916 3868911 (1.68:1) DP-SM 3868916 3868912 (1.78:1) DP-SM 3868850 3868911 (1.68:t) DP-SM 3868850 3868912 (1.78:1) DP-SM 3868916 3868911 (1.68:1) DP-SM 3868916 3868912 (1.78:1) DP-SM 3868289 3868637 (1.59:1) DPX-S1 3868289 3868638 (1.68:1) DPX-S1 3868289 3868639 (1.78:1) DPX-S1 3868289 3868637 (1.59:1) DPX-S1 3868289 3868638 (1.68:1) DPX-S1 3868289 3868639 (1.78:1) DPX-St iv Section 1 General Information Table of Contents Conversion Charts Metric .................................. 1=15 Drill .................................... 1-16 Gasolines Containing Alcohol ................. 1-6 Gasoline Requirements ...................... 1-5 introduction ................................ 1-2 Periodic Maintenance Chart .................. 1-18 Symbols .................................. 1 +17 Torque Specifications, General ............... 1-18 Troubleshooting -Engine Guides .............. 1-8 Troubleshooting - System Isolation ............. 1-7 Tuning the Engine ........................... 1-5 Safety Warning Before working on any part of a Volvo Penta sterndrive, read the section called Safety at the end of this manual. Introduction This service manual covers "BY" model Volvo Penta Sterndrives. It is divided into sections concerning various systems and assemblies. Refer to the Contents to locate the section covering the system or assemblyrequiring service. Each section title page has an additional listing that will describe the section’s 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. GoodService Practice Service required for an Volvo Penta Stern Drive is generally one of three kinds: ¯ Normal - care and maintenancewhich incPudes putting a new stemdriveinto operation, storing engines, lubrication, and care under special operating conditions such as salt water and cold weather= ¯ Operating - malfunctionsdue to improper engine or drive mounting,propeller condition or size, boat condition, or the malfunctionof some part of the engine. This includes engine servicing procedures to keep the engine in prime operating condition. ¯ Completedisassembly - 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 expenseto the owner. Whenrepairing 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. Do not operate engine out of water even momentarily. If operated in a test tank, use the proper test wheel. Failure to do so can damagewater pump, overheat engine, or allow excessive engine RPM. 1-2 Fuel Sys/eng 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 becomingmisplaced. Clean an engine that is excessively dirty Ic)efore 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. Use proper lifting and handling equipment. Working on sterndrives without proper equipment can cause damage and personal injury. Alwaysuse clean, fresh fuel when testing engines. Troubles can often be traced to the use, of old or dirty fuel. Service Policy Whetherwithin or following the warranty period, Volvo Penta has a constant interest in its products. It is a Volvo Penta policy to provide dealers with service knowledge so they can give professional service demanded by today’s consumer. The Volvo Penta service schools, frequent mailing of Service and parts information bulletins, letters and promotions, special tools, and this service manual represent our continuing efforts to assist dealers in giving consumers the best and most prompt service possible. This service manual covers all phases of servicing a Volvo Penta sterndrive unit. If a service question does not appear to be answeredin this manual, you are invited to write to the Volvo Penta Service Department for additional help. Always be sure to give complete information, including engine model number and serial number. Be sure that you are familiar with the Volvo Penta Warranty statement. If you have any questions, write the Volvo Penta Service Department. If other than genuine Volvo Penta replacement components or parts are used, Volvo Penta may refuse subsequent warranty claims involving that engine. Whena brand-name product or specific tool is called for, another item may be used. However, the substitute must have equivalent characteristics, including type, strength, and material. You must determine if incorrect substitution could result in product malfunction and personal injury to anyone. To avoid hazards, equivalent products which are used must meet all current US Coast Guard Safety Regulations and ABYC standards. Replacement Parts When replacement parts are required, always use genuine Volvo Penta parts, or parts with equivalent characteristics, including type, strength, and material. Failure to do so may result in product malfunc tion and possible injury to the operator and/or passengers. Parts CataJogs Parts Catalogs contain exploded views showing the correct assembly of all parts, as well as a compaete listing of the parts for replacement. These catalogs are helpful as a reference during disassembly and reassembly,and are available from Volvo Penta. Special Service Tools Volvo Penta has specially designed tools to simplify some of the disassemblyand assembly operations. These tools are illustrated in this Service Manual, in many cases in actual use= All Volvo Penta special tools can be ordered from Volvo Penta Genuine Parts division. individual purchasers of Service Manuals must order Special Tools through an authorized dealer. Product References, illustrations & Specifications Volvo Penta of the Americas reserves the right to make changes at anytime, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts at any time without incurring any obligation to equip sameon models manufactured prior to date of such change. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. The right is reserved to make changes at anytime without notice. All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only. The continuing accuracy of this manual cannot be guaranteed. //~ Safety Related 1-4 Fuel Sys/eng Tuning The Engine The purpose of an engine tune-up is to restore power and perfor mancethat has been lost through wear, corrosion, or deterioration of one or more parts or components, in the normal operation of an engine, these changes can take place gradually at a number of points, so that it is seldom advisable to attempt an improvement in performanceby correction of one or two items only. Time will be saved and more lasting results will be obtained by following a definite and thorough procedure of analysis and correction of all items affecting power and perfo;rmance. Refer to the Engine Service Manual for all tune-up specifications. Gasoline Requirements Volvo Penta sterndrive models are designed for maximum performancewith the use of gasoline with the following minimum or higher octane specification: ¯ Anti-Knock index Number (AKI) - ¯ Research Octane Number (RON)- EF! Models Only: Some marinas sell fuel with lead additives. Do not use such fuel as it may plug the fuel injectors. Premiumgrade fuels contain injector’ cleaners and other additives that protect the fuel system and provide optimum performance. The use of premium grade fuels is strongly recommended. CarburetedModelsOnly: Use of lead-free or leaded gasoline is acceptable. if fuels with 89 AKI (93 RON) octane or higher are not available, lower octane fuels, with a minimum of 87 AKI (90 RON) octane, can be used. When lower octane fuels are used, a slight decrease in power can be expecled. Engine damage resulting from the use of gasoline with octane lower than 87 AKI (90 RON) is considered misuse of the engine and will void the engine warranty. Volvo Penta suggests the use of 89 AKI or higher fuels. These fuels have additives that are beneficial to maximum of service components. engine performance and long life To prevent gum formation and corrosion in the fuel system, use DuraPlusTM Marine Fuel Stabilizer in the gasoline. ~ Danger! Gasoline is extremely flammable and highly explo sive under certain conditions. Always stop engine and do not smokeor allow open flames or sparks near the boat when refuel ing gas tanks. When filling the gas tank, ground the tank to tlhe source of gasoline by holding the hose nozzle firmly against the side of the deck filler plate, or ground it in some other manner. This action prevents static electricity build-up that could cause sparks and ignite fuel vapors. FueISys/eng ~ Safety Related Gasolines Containing Alcohol Many gasolines being sold today contain alcohol. Two commonly used alcohol additives are Ethanol (ethyl alcohol) and Methanol (methyl alcohol). See the Owner’s Manual for your boat to determine if the boat’s fuel system is compatible with alcohol blended fuels, if it is compatible, your engine may be operated using gasolines blended with no more than 10% Ethanol (ethyl alcohol) meeting the minimum octane specification. Do not use any gasoline which contains METHANOL (methyl alcohol). I~ Serious damage to the boat or engine fuel systems will result from the continued use of fuel containing METHANOL (methyl alcohol). If you use gasoline containing aacohol, be aware of the following: @ The engine will operate leaner with alcohol blended fuel. This may cause engine problems such as vapor lock, low speed stall, or hard starting. ® Alcohol blended fuels attract and hold moisture. Moisture inside fuel tanks can cause corrosion of the tank material, inspect fuel tanks at least annually. Replace fuel tanks if inspection indicates leakage or corrosion. @ inspect non-metallic parts of fuel system frequently andreplace if excessive stiffness, deterioration or fuel leakage is found. leakage can contribute to a fire and/or explosion. Troubleshooting-System Isolation The following is to help you isolate a malfunction of one or possibly several systems. After determining which systems are related to the malfunction, refer to the individual system troubleshooting charts to isolate the specific cause. Cranking System Engine Ignition Does Not System Run Engine should (:rank at specified RPM. if not, check for: 1. Discharged or dead battery 2. Loose or corroded connections 3. Cranking System Troubleshooting Chart Must have good spark at spark plugs. If not, check the: 1. Distributor cap and rotor 2. Coil and spark plug leads 3. Ignition timing 4. Automatic spark advan¢:e 5. Ignition Troubleshooting Chart Carburetor accelerator pump should squirt fueU into venturi when throttle is advanced. If not, check the: 1. Fuel tank, valves, and lines 2. Fuel pump and tinter 3. Carburetor and fiater 4. Boat Fuel System Troubleshooting Chart 5. Carburetor Troubleshooting Chart 6. Engine Fuel System Troubleshooting Chart Check the following: 1. Compression 2. ignition system 3. Fuel and carburetor system 4. Lubrication system 5. Cooling system 6. Vertical drive and propeller 7. Vertical drive gear ratio and installation 8. Engine Troubleshooting Guides Troubleshooting -Engine Guides EFI Engines Only: Refer to GMEFI Diagnostic Service Manual. These guides ,were written to help you trace the symptoms of the trouble to the source, without having to read through and prove every possibility. Much of the information here will be familiar to well informed mechanics. Also, many factors will seem insignificant but when you think of it, usually the toughest problem to troubleshoot is caused by the smallest error. The greatest aid to solving a service problem is information. Start gathering information from the boat operator and write it on his job card or work ticket. Find out pertinent facts, such as: o When did this trouble start? ¯ How was the boat loaded? ¯ Did the trouble occur suddenly, or start gradually? Analyze this information and try to match it to similar situations you have experienced in the past. Keep in mind the fundamental rules: 1. COMPRESSIONMixture 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 necessary for the engine to run. Use these charts and the service information they refer to. Do not try to remember tolerances, settings, measurements, etc., as they are written in the service manual. Leave your mind free to analyze the problem. Following is a list of the troubReshooting guides which may be found on the pages indicated. Title .......................................... Page 1. Engine Will Not Crank ........................... 1-9 2. Engine Cranks, But Will Not Start .................. 1-9 3. Hard Starting -Cold Engine ...................... 1-10 4. Hard Starting -Hot Engine ...................... 1-10 5. Engine Runs Rough ............................ 1-11 6. Engine Noises and Vibrations .................... 1-11 7. Engine Overheats ............................. 1-12 8. Engine Dies Out ............................... 1-13 9. Engine Won’t Reach Operating RPM ............... 1-13 10. Defective Engine Lubricating System .............. 1-14 11. Low Battery "Voltage After Short Storage ........... 1-14 1-8 FuetSys/eng Engine Wili Not: Crank ....... ® Battery condition: weak, dead, sulfated, bad cells ® 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 System section of the Emectri cal/lgnition manual Engine Cranks, But Will Not Start e Primary circuit wiring from ignition switch to ignition coil/ignition module o Secondary circuit wiring from coil to spark plug ¯ Spark plugs, for proper gap, fouling, burned electrodes, cracked or dirty insulator ¯ E.S.A. system, if so equipped, for improper activation ¯ See respective Ignition System section of the ElectricaU ignition manual ® Quantity and condition of fuel in boat tank ¯ Operation and flow capacity of boat anti-siphon valve ® 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 ¯ Fuel pump vent hose for signs of fuel or oil that would indicate a fuel pump failure ¯ Fuel pump operation for correct vacuum and pressure readings ® External fuel filter canister and carburetor for clean tinters ¯ Carburetor accelerator pump for fuel discharge ® See the appropriate Fuen System section = 0 |=O = o See Engine manual Hard Starting -Cold Engine Ask these questions first: o ® " ~ . D e " ® Carburetor choke operation and adjustment ¯ Fuel lines for obstructions ® For debris inside fuel tank ® See the appropriate Fuel System section e For clean external canister and carburetor fuel filtgrs o Empty carburetor float bowl due to evaporation ¯ Water in fuel due to condensation ¯ Fuel quality deterioration ® See the appropriate Fuel System section ® Carburetor choke operation and adjustment ¯ Carburetor accelerator pump ¯ Fuel system for leaks, dirt, or obstructions ¯ Engine timing and ignition system ¯ See General information, ignition System sections in the Electrical/Ignition and Engine Service manuals e See the appropriate Fuel System section Hard Starting -Hot Engine Ask these questions first: o e . A , l0 " ® Carburetor choke operation and adjustment ¯ See the appropriate Fuel System section A. e= 0 e ¯ Brand, type or octane of fuel ® Spark plugs ¯ Water in fuel ® Condition of battery and cables ¯ Starter motor for overheat damage ¯ Ignition system primary circuit ® Ignition coil/ignition module ¯ Engine timing ® Carburetor choke operation and adjustment ¯ See General information, ignition System sections of the Electrical/Ignition and Engine Service manuals ¯ See the appropriate Fuel System sections FuelSys/eng 1 - 10 Engine Runs Rough ¯ Idle speed and idle mixture ¯ Engine timing and spark plugs ¯ Fuel pump pressure ¯ Water or contaminants in fuel ¯ Carburetor or manifold vacuum leak ® Internal carburetor fuel leak ¯ See General information, Ignition System sections of the Electrical/Ignition and Engine Service manuals ¯ See the appropriate Fuel System section n *.11 e =’e a" L ¯ Air leak on ,suction side of fuel system ¯ Too low octane fuel ¯ Ignition system secondary circuit ¯ Engine timing e Wrong mootel or size carburetor, improper main jets or power valve, defective secondary fuel circuit, secondary vacuum diaphragm failure ¯ External canister and carburetor fuel filters ¯ Fuel pump pressure ¯ Engine compression ¯ Water or contaminants in fuel, water in cylinders ¯ See General information, Ignition System sections of the Electrical/Ignition and Engine Service manuals ¯ See the appropriate Fuel System sections Engine Noises and Vibrations ................. . *Q ¯ " ¯ Rapping only when starting (oil too heavy for prevailing weather, varnish on lifter, oil needs to be changed) ¯ Intermittent rapping (leakage at lifter check ball) ¯ Idle noise (excessive leak down rate, faulty check ball seat) ¯ Generally noisy (excessive oil in crankcase, stuck lifter plunger) ¯ Loud noise at operating temperature (scored lifter plunger, fast leak down rate, oil viscosity too light for prevailing weather or operating temperatures) ¯ See Engine manual Engine Noises and Vibrations, Cont. ¯ Improper tuning ® Incorrect spark plug wire routing ¯ Use higher octane fuel ¯ See General information and appropriate ignition Sys tem sections of the Electrical/ignition and Engine Serv ice manuals e Water pump ¯ Loose belts, pulleys ¯ See Cooling System section of the Engine manual ¯ Loose, broken or worn engine mounts e Loose lag screws holding mounts to stringer o o~o ¯ " e "" ® Loose bolt(s) ¯ Loose pulley, worn bearings ® Loose mounting bolts ® Failed U-joints or gimbal bearing ¯ Damaged internal drive components ® Worn, bent or broken propeller hub or blades ® Loose, worn or damaged engine coupler Engine Overheats -Check" ¯ Actual engine temperature by verifying with an accurate thermometer ¯ Gauge operation and wiring circuit ¯ Sending unit operation and wiring circuit ® Powerhead water pump and belt ® Water intake screens for blockage ® Thermostat ® Water supply hoses ® 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 1 - 12 Fue,Sy,,er~ Engine Dies Out ~:-=-, ¯ Fuel gauge operation and wiring ¯ Fuel level in tank e Water or debris in fuel ¯ Fuel pickup tube and screen blockage e Fuel tank vent blockage e Plugged external canister or carburetor fuel filters e Air leak on suction side of fuel system o Fuel leak on pressure side of fuel system e Inoperative, restricted or incorrectly sized anti-siphon va I ve ¯ Boat fuel nines too small in diameter ¯ Fuel pump pressure and suction ¯ Carburetor cleanliness and operation ¯ See the appropriate Fuel System section ¯ Primary and secondary ignition circuits ¯ Ignition switch ® Circuit breakers ¯ Wiring between engine and dash ¯ Main engine harness wiring ® See Gener~RI information and appropriate Ignition Sys tem sections of the Electrical/Ignition manual ® Vertical drive for internal damage ® Oil pressure gauge and crankcase oil level ® Temperature gauge and cooling system operation ® Internal engine components as required Engine Won’t Reach Operating RPM -Check: ..-, __ ¯ Fuel type or octane ® Propeller pitch or diameter, damaged blades, slipping hub ® Crankcase oil vomume ® Marine growth on hull and drive ® Wrong vertical drive gear ratio ® Operating at high altitude ® Restricted carburetor air intake ® Restricted exhaust outlets in engine, transom bracket or drive ¯ Poor cylinder compression ® Carburetor size and type correct for engine ¯ Fuel pump pressure and vacuum ® Boat overloaded, or load improperly placed ® Engine overheating ® Engine timing and ignition system operation ¯ Remotecontrol cables and linkage for proper attachment and travel Defective Engine Lubricating System ¯ Clogged or incorrect oil filter ® Worn oil pump gears, cover or shaft ¯ Worn or collapsed oil pump relief valve spring, or foreign material caught on valve seat ® Oil pump relief valve plunger loose in cover ® Damaged filter bypass grommet o Clogged oil pickup screen, broken tube or housing o Plugged crankshaft or block oil galleys e Dirty or defective hydraulic lifters, clogged push rod passages o Poor quality, incorrect viscosity or quantity of oil o Incorrect hose routing on remote filter systems e Water in crankcase oil from condensation, defective head gasket, oil cooler, or cracked manifold/block water passages ® Oil gauge~warning horn operation and wiring ® Engine temperature ® Oil pressure gauge and ,warning horn sender operation and wiring Low Battery Voltage After Short Storage ¯ All electrical accessories including ignition circuit off ® Disconnect main battery negative cable from battery ® Connect ammeter or 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 movement no 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 each boat electrical accessory 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 problem is found ® Repair or replace components as necessary FuolSys/er~g 1 - 14 METRIC CONVERSION CHART inches X 25.4 feet X 0.3048 yards X 0.9144 miles X 1.6093 inches X 2.54~ 2 inchesX 645.16 2 inchesX 6.452 2 feetX 0.0929 2 yardsX 0.8361 acres X 0.4047 2 milesX 2.590 3 inchesX 16387 3 inchesX 16.387 3 inchesX 0.01639 quarts X 0.94,635 gaIIons X 3.7854 3 feetX 28.317 3 feetX 0.02832 fluid oz X 29.57 3 yardsX 0.7646 ounces (av) X 28.35 pounds (av) X 0.4536 tons (2000 lb) X 907.18 tons (2000 Ib) X 0.90718 ounces-f (av) X 0.278 pounds-f (av) X 4.448 kilograms -f X 9.807 2 feet/secX 0.3048 2 inches/secX 0.0254 = millimetres (mm) = metres (m) = metres (m) = kilometres (kin) = centimetres (cm) 2) = millimetres2 (mm 2) = centimetres2 (cm 2) = metres2 (m 2) = metres2 (m= hectares (104 2) (ha} 2) = kilometres2 (km z) = millimetres 3 (mm 3) = centimetres3 (cm = fitres (I) = Iitres (I) = litres (I) = litres (t) s) = metres3 (m= millilitres (ml) 3) = metres3 (m = grams (g) = kilograms (kg) = kilograms (kg) = metric tons (t) = newtons (N) = newtons (N) = newtons (N) 2) = metres/sec2 (m/S 2) = metres/sec2 (m/Sfoot-pounds calories 8tu watt-hours kilowatt - hrs miles/gal Note: X 1.3558 X 4.187 X 1055 X 3500 X 3,600 = joules (j) = joules (j) = joules (j) = joules (j) = megajoules (M J) X 0.42514 = kilometrestlitre (km/l) 235.2/(mi/gal) = litres/100 235.2/(litres/100 kin} = mi/gal 2) footcandles X 10.76 = lumens/metre2 (Im/m inches HG (60°F} pounds/sq in inches H20 (60°F) bars pounds/sq ft horsepower ft-lbf/min X 3.377 X 6.895 X 0.2488 X 100 X 47.88 X 0.746 X 0.0228 °Celsius = 0.556 X (°F -32) °Fahrenheit= (1.8 X °C) +32 pound-inches pound-feet miles/hour feet/sec kilometres/hr miles/hour X 0.11299 X 1.3558 X 1.6093 X 0.3048 X 0.27778 X 0.4470 = kilopascals (kPa) = kilopascals (kPa) = kilopascals (kPa) = kilopascals (kPa) = pascals (Pa) = kilowatts (kW) = -watts (W) = newton-metres (N.m) == newton-metres (N.m) = kilometres/hour (km/h} = metres/see (m/s) = metres/sec (m/s) = metres/sec (m/s) Drill Size Conversion Chart SHOWINGMILLIMETER SIZES, FRACTIONALAND DECIMAL INCH SIZES AND NUMBER DRILL SIZES MilH-Dec. Frac-Num- Milli- Dec. Frac-Num-Milli- Dec. Frac- Num- Milli-Dec. Frac- Num- Milli-Dec, Frac- Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tionaE .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 %6 .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 ts/32 .35 .0138 .... 0760 48 .... 1660 19 .... 2811 K 12.0 .4724 .... 0415 79 1.95 .0767 4.25 ,1673 7.14 .2812 9/32 ... 12.30 .4843 31/e4 .39 .0156 %4 ... 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 ~%4 7.3 .2874 13.0 .5118 .45 .0177 2.05 .O8O7 .... 1730 1’7" .... 2900 L 13.10 .5156 3%4 .... 0180 77 .... 0810 46 4.4 .1732 7.4 .2913 13.49 ,5312 t7/32 .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.t5 .0846 .... 1800 15 7.54 .2968 ~s/s4 ... 14.0 .5512 .55 .0217 .... 0860 44 4.6 .1811 7.6 .2992 14.29 .5624 9/~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 14.68 .5781 3%4 .... 0240 73 .... 0890 43 4.75 .1870 7.75 .3051 15.0 .5906 .... 0250 72 2.3 .0905 4.76 .1875 %6 7.8 .3071 15.08 .5937 19/32 .65 .0256 2.35 .0925 4.8 .1890 1"2" 7.9 .3110 15.48 .6094 3%4 .... 0260 71 .... 0935 42 .... 1910 11 7.94 .3125 %6 ... 15.5 .6102 .... 0280 70 2.38 .0937 3/32 ... 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 .79 .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 43//64 .... 0320 67 .... 1015 38 5.16 .2031 W84 mB 8.33 .3281 2%4 ... 17.46 .6875 11/16 .... 0330 68 2.6 .1024 .... 2040 6 8.4 ,3307 17.5 .6890 .85 .0335 .1040 37 5.2 .2047 .... 3320 Q 17,86 .7031 45/64 .... 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 23/32 .... 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 47/64 .95 .0374 1100 35 5.4 .2126 8.73 .3437 1½2 ... 19.0 .7480 .... 0380 62 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 7/3z .,. .... 3480 S 19.5 .7677 .... 0400 60 2.9 .1141 5.8 .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 s%4 .... 0420 58 .... 1200 31 5.75 .2263 9.1 .3583 20.5 .8071 .... 0430 57 3.1 .1220 .... 2280 1 9.13 .3594 23/84 ,.. 20.64 .8125 13/18 1.1 .0433 3.18 .1250 % ... 5.8 .2283 9.2 3622 21.0 .8268 t.15 .0452 3.2 .1260 5.9 .2323 9.25 .3841 21.04 .8218 s%4 .... 0465 56 3.25 .1279 .... 2340 A 9.3 .3861 21.43 .8437 27/32 1.19 .0469 3/84 ... .... 1285 30 5.95 .2344 ~8/64 ... .... 3680 U 21.5 .8465 1.2 .0472 3.3 .1299 6.0 .2362 9.4 .3701 21.83 .8594 s%4 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 % . . . 22.23 .8750 7/s .... 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 s7/64 .... 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 ~/32 1.45 ,0570 .... 1440 27 6.35 .2500 ¼ E 9.8 .3858 !23.42 .9219 59/84 1.5 .0591 3.7 .1457 6.4 .2520 .... 3860 W 23.5 .9252 .... 0595 53 .... 1470 26 6.5 .2559 9.9 .3839 23.8t .9375 W~6 1.55 .0610 3.75 .1476 .2570 F 9.92 .3906 2%4 ... 24.0 .9449 1.59 .0625 ¼6 ... .... 1495 25 6.6 .2598 10.0 .3937 24.21 .9531 sl/64 1.6 .0629 3.8 .1496 .2610 G .... 3970 X 24.5 .9646 .... 0635 52 .... 1520 24 6.7 .2638 .... 4040 Y 24.61 .9687 31/32 1.65 .O649 3.9 .1535 6.75 .2657 1%4 ... 10.32 .4062 13/32 . .. 25.0 .9843 1.7 .0669 .... 1540 23 6.75 .2657 .... 4130 Z 25.03 .9844 ~/64 .... 0670 51 3.97 .1562 %2 ... .... 2660 H 10.5 .4134 25.4 1.0000 1 DR2949-ENG 1-16 FuelSys/eng SYMBOLS Certain symbols or combinations of symbols may appear on your Volvo Penta Stern Drive or on their accessories. It is very important thalf you understand their meaning or purpose, ff any symbol is not clearly understood, see your Dealer. "Safety Warning" SymboRs ~l~ --~ ............................ ® Po,so=olJs e, Risk of serious injury ¯ Be careful Fire hazard ~ ¯ Follow instructions Contents under pressure ’~ "Position indicator" Symbols Shift positions NEUTRAL RAISE! LOWER FORWARD REVERSE .______________________________ ..................... "Condition" Symbolls ® Voltmeter Hour meter ¯ Ammeter ~(Tachometer W Voltmeter Fuel filter Oil filter 0 Water temperatu re Emergency stop Oil pressure 0A m "instructional" Symbols ¯ Use gasoline Read Operator’s Manual ¯ Gasoline is present ~ before operating product Oil fill DR3847 Perodic Maintenance Chart ,&k Items marked ~ Safety Warning are safety related service points to prevent mechanical failures, fire and explosion. Make sure the safety related service is performed at these points and at the intervals specified. Service Point Every 25 Hours or as Specified Every 50 Hours or as Specified Recommendations Carburetor Annually or as needed Adjust idle mixture and idle r/re. Clean linkage Flame Arrestor-Mounting Clean and check annually Tighten nut. Replace if damaged Fuel Filter Annually Replacefuel filter Fuel Pump Checktransparent vent tube for presence of fuel or oil Replace leaking fuel pump. Check for leaks after starting engine .~ Fuel System Checkfor leakage dady Tighten connections Replace with specified Volvo Penta components r FueITank Checkfor water in fuel Keeptank filled with recommendedfuel Checkfor excessive stiffness, Non-MetalhcFuel Hoses deterioration and/or leakage every 50hours or monthly, whichever Replace as necessary with A.B.Y.C. approved components. comesfirst General Torque Specifications The following specifications are for nut and screw sizes not having specific torque recommendations. U.S. Screw Sizes ft. lb. N.m Metric Thread Sizes ft. lb. N.rn 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. 12 3 -4 4.1-5.4 M10 28 -40 38 - 54 1/4 - 20 5 - 7 6.8-9.5 M12 50- 71 68- 96 5/~6- 18 12- 14 16 -19 M14 80- 114 108- 155 3/8 - 16 20 - 25 27 -34 32 - 40 43 -54 7/16-14 Pound-inches x 0.11298 = newton-meters N.m Pound feet x 1.3558 = newton-metersN,m 1-18 Fuel Sys/eng NOTES FuelSys/eng 1 - 19 NOTES 1-20 Fuelsys/eng Section 2 Fuel Systems -Carbureted Models Table of Contents Carburetor Operation ............................. 2-3 Carburetor Replacement 2V Models ................................... 2-12 4V Models ................................... 2-24 Carburetor Service and Adjustments 2V Models ................................... 2-11 4V Models ................................... 2-23 I=lectric Fuel Pump-4.3GL .... 2-38 and GS; 5,0 GL; 5.7 GS Circuit Breaker Replacement ................... 2-41 Filter Bracket Replacement ..................... 2-42 Operation ................................... 2-38 Relay Ohmmeter Tests ........................ 2-47 Electric Fuel Pump Replacement................ 2-39 Specifications ................................ 2-52 Troubleshooting .............................. 2-43 Wiring Diagram 4.3 GL and GS ............................. 2-48 5.0 GL and 5,7 GS .......................... 2-48 Fuel Filter Replacement 3,0 GS ....................................... 2-6 Canister ..................................... 2-7 Carburetor ................................... 2=7 Fuel Pump and Vent Hose Pressure Testing .............................. 2-4 Replacement, 3.0 GS ........................... 2=5 Specifications .................................. 2-5 Vacuum Testing ................................ 2-4 Specifications, Carburetor ......................... 2=52 Tanks, Lines, Valves, and Fittings .................... 2-9 TorqueValues-All Models ......................... 2-52 Troubleshooting Boat Fuel System .............................. 2-9 Carburetor .................................. 2-36 Electric Pump Fuel System ...................... 2-43 Engine Fuel System ............................ 2-50 Safety Warning Before working on any part of the fuel system, read the section called Safety at the end of this manual. The original mounting, support, and routing of the fuel system parts conform with US Coast Guard requirements. It is important to maintain the original mounting, support, and routing after servicing the fuel system. Gasoline is extremely flammable and highly explosive under certain conditions. Ensure good ventilation. Do not smoke or allow open frames or sparks near fuel system or in engine compartmentwhile servicing. Whenadjusting a carburetor while the engine is running or being cranked, use extreme care to avoid getting hands, fingers, or clothing caught in the alternator and water pump belts, pulleys, and other moving parts. Materials Required: ¯ Gasket Sealing Compound ° Uquid Neoprene ° Pipe Sealant with Teflon Tools Required: ¯ Vacuum Gauge ¯ Fuel Pressure Gauge ° #2 Clutch Type Screwdriver 2-2 Fuel Sys/eng Carburetor Operation The carburetor is a metering device for mixing fuel and air. At idle speed, an engine requires a mixture of about 8 parts air to 1 part fuel. High speed mh(. Do not nick or cut O-ring on threads. This O-ring is made of a special fuel resistant material.. Substitution of parts of unknown quality could result in a fuell leak, and the possibility of fire and explosion. [~ 2. Screw filter bracket assembly into pump. Hold lower’ pump end cap@with an open end wrench and tighten adaptorto 8-10 ft. Ibs. (11-14 N-m). Z~ ff pump end cap is not held when installing adapter, end cap mayrotate and damage internal O-ring that seals pump against external fuel leakage. [~ 3. Slide pump up through grommet ® and install two bolts, @. Tighten bolts to 20-25 ft. Ibs. (27-34 N.m). [~ 4. Before installing upper elbow, turn nut @ up against head of elbow. Slide washer and O-ring ® up against nut. Do not nick. or cut O-ring on threads. Z~ This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel! leak, and the possibility of fire and explosion. 30628 30635 30626 30634 FuelSy,’,/eng ~ Safety Related 3-21 [~] ~ 5. Screw elbow all the way into pump outlet, then back it off until it aligns with the fueE line. Attach fuel line, and while holding elbow, tighten line fitting securely. [~ ~ 6. Screw elbow Rock nut (~ down against pump outlet. Hold pump end cap (A with an open end wrench and tighten nut to 60-84 in. Ibs. (6,8-9,5 N.m)= Z~lf pump end cap is not held when tightening nut, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. F~ 7. Align connector tabs © and push connector onto pump suppressoruntil it clicks into place, ff the suppressor holes (A are open, coat them with NeopreneDip to prevent water entry. 8. Install tie strap to hold electrical leads against pump body. Z~, 9. Connect boat fuel line. Attach negative cable to the battery. Tighten nut securely. Run engine and check for fuel leaks. 3-22 30631 30621 30639 30641 FuelSys~eng Fuel Reservoir Removal 1. Loosen hose clamps (~ and remove water inlet hose and outlet hose @ from fuel reservoir. 2. Cut the tie strap, then unplug the electrical connector from the high pressure fuel pump. ~] 3. Loosen clamp 0 and remove reservoir vent hose @ from reservoir. 37638 4. Remove low ipressure inlet line ®, high pressure outlet line (~, and fuel return Fine (~ from the reservoir. 5. Loosen clamp, ® and remove cooling outlet hose @. 37639 37648 37641 Lid 6. Remove two screws ~) securing reservoir to the engine. Remove the reservoir° Float Level Setting 1. Unscrew the reservoir cover screws and remove the cover. Discard the cover gasket. ~] 2. Turn the reservoir cover over to allow the float to seat the float needle. [~ 3. Measure from the top of the float to the inside surface of the cover. Adjust the float to a 3/16 inch (4,76 mm) measurement by lightly bending the adjustment tab ©. After setting the float level, ensure free float movementon the float pivot pin. [~ Do not force the viton tipped float needle against the needle seat or the resilient needle tip may be damaged. 4. Place a new cover gasket on top of the reservoir. Install the cover and secure with eight screws. Tighten the screws to 25-35 in. Ibs. (2,8-4,0 N-m). Installation [~] 1. Connect the fuel reservoir coolant inlet nipple to the inlet hose @. Install the fuel reservoir and secure with two screws (~). Tighten the screws to 24-36 ft. Ibs. (38-49 N-m). [~ 2. Attach thermostat housing cooling hose (~ to reservoir and secure with clamp (~. E~ z~ 3. Attach fuel rail high pressure fuel line @, fuel return line ®, and the low pressure fuel line O to fuel reservoir. Tighten all line fittings to 10-12 ft. robs. (13,6-16,3 N.m). 37643 © I DR4549 37647 37648 Z~ Safety Related 3-24 FuelSys/eng [~ Z~ 4. Attach upper intake manifold vent hose (~ to reser-. voir. Secure with clamp ® to prevent leakage of fuel fumes. [~ 5. Connect two -wire connector ~) to fuel pump. Secure with tie strap (~. DE] 6. Attach outlet (~ cooling hoses to the reservoir. Secure the inlet and outlet hose,,; with hose clamps @. 7. Energize fuel pumps and check for leaks. Electric Fuel Pump -High Pressure Remova0 ~=-TNote [’"~J Pumpservice may be done with the reservoir either on or off the engine. 1. Removethe high pressure fuel line to the throttle body. ~=~ ~ 2. Make note of the position of the elbow, then back off the elbow lock nut ®. Unscrew the elbow from the pump. [~ 3. Unscrew the two screws (~) securing the end bracket ® the reservoir. Remove the bracket from the pump. 37650 37651 37652 37644 4. Unscrew the banjo nut from the end of the pump and remove the pump. Discard aH O-rings. Pumpinstallation [~ 1. Lubricate one new small O-ring ~) with engine oil and place it on the threaded end of the elbow. Lubricate one large O-ring ® with engine oil. Place it on the banjo nut in the O-ring groove closest to the hex head. Z~ These O-rings are made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. [~ 2. Install banjo nut @ into hole in reservoir cover. Lubricate a second new large O-ring ® with engine oil. PBace the O-ring on the threaded end of the banjo nut. Z~ This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. [~ DE] 3. Thread the banjo nut into the high pressure fuel pump. Position the pump at a 45 ° angle. Hold pump end cap with a wrench, and tighten the banjo nut to 18-22 ft. Ibs. (24,4-29,8 N.m). Z~ if pump end cap is not held when instaBing banjo nut, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. 32122 ® ® 37646 ® 32121 Z~ Safety Related 3-26 FuelSys/eng E=~ 4. Place fuel pump support bracket @ over the end of the pump. Secure the bracket to the reservoir cover with two screws ~. Tighten the screws to 25-35 in. Ibs. (2,8-4,0 N.m). EB 5. Attach the elbow to the end of the pump. Position the elbow as noted in the removal procedure. Screw the elbow lock nut ® down against the pump outlet. Homdthe elbow @ with an open end wrench and tighten nut to 60-84 in. lb. (6,8-9,5 Nora). ~lf elbow is not held when tightening nut, elbow may rotate and damage internal O-ring that seals pump against external fuel leakage. Circuit Breaker [=8~ Volvo Penta’s EFI engines have four circuit breakers as protection devices. ,~ A 12.5 amp circuit breaker protects the fuel injector relay and ECM. A 50 amp circuit breaker protects the trim/tilt motor. A 50 amp circuit breaker protects the main engine harness. A 20 arr~p circuit breaker protects the fuei pump relay and circuit. Modelshave a 10 amp circuit breaker, located on the trim/tilt pumpto protect the pump or circuit fails, relay. If this component the ECM will not store a service code in the memory. Circuit Breaker Repmacement 1. Makea note of the lead position, then remove all the leads from the circuit breaker. Remove circuit the screws and nuts, and lift breaker out of bracket. 2.. Install new circuit breaker and secure with screws and nuts. Tighten screws to 20-25 in. lb. (2,3-2,8 N,,m). 3. Attach the leads to their original positions on the circuit breaker and secure with the nuts° Tighten the nuts to 20-25 in. lb. (2,3-2,8 N,=m). Coat the terminals with NeopreneDip. ® 37644 37645 DR4640 3=27 FLel Sys/eng Relay E~ Replace the relay ® by pulling it off its mounting bracket. Install the relay by aligning the terminals of the relay with the bracket. Push the relay in until it seats. Filter Bracket [~Q~el The OMC electric fuel pump filter has an internal seal around the fuel exit point that prevents leakage and drain back. Do not substitute other filters that may be similar in appearance. To replace filter canister, refer to Fuel Fi|ter Replacement elsewhere in this section. 1. Remove fuel pump and filter bracket assembly from mounting bracket. 2. Unscrew fuel inlet elbow and save for installation on new bracket. 3. Clamp filter bracket in a vise and unscrew adaptor and pump assembly. Discard bracket. 4. Thoroughly clean adaptor threads to remove old sealer, then apply ~ Pipe Sealant With Teflon to the threads. 5. Clamp new bracket in a vise. Screw in adaptor and pump assembly, and tighten to at least 10 ft. Ibs. (14 N.m). Continue tightening adaptor to achieve proper pump/bracket directional alignment. Do not exceed 32 ft. Ibs. (43 N.m) torque. 6. Thoroughly clean threads of inlet elbow to remove old sealer, then apply ~ Pipe Sealant With Teflon to the threads. Screw in elbow and tighten to at least 12 ft. Ibs. (16 N-m). Continue tightening elbow to achieve proper directional alignment. Do not exceed32 ft. Ibs. (43 N.m) torque. 7. install fuel pump and filter bracket assembly in mounting bracket. Z~ 8. Run engine and check for fuel leaks. Z~ Safety Related 3-28 FuelSys/eng TroubleshootingElectric Pump(s) Checking Engine Fuel System Start by verifying the pumps are receiving a minimum of 12.0 + 1 volt. Remove the connector from each pump suppresser. Disable ignition to prevent engine from running, then crank engine and check yellow/green lead with a voltmeter. Turn key off, then check connector black lead with an ohmmeter for a good ground. If voltage is not as specified, or ground path is suspect, check: ® relay and bracket circuit breaker ® wiring related to all of the above Ensure all items are functioning correctly before proceeding. As voltage to the pump drops, so will its output capability. 2. Once it has been established that the pumps are receiving proper voltage, separate the engine fuel system from the boat’s fuel system. Disconnect the supply line at the pump’s fuel filter, and place a pick-up hose in a vented fuel container. The pick-up hose must have a minimum I.D. of 3/8 in. ~ WARNING: Do not connect engine fuel system to any supply system having a pressure producing deviice such as an outboard fuel tank with primer bulb, or another electric fue~ pump located elsewhere in the boat or at the fuel tank. The engine fuel pumpsare sensi= tive to additional fuel pressure, and this will add to its own output.The result will be a continually flooding fuel reservoir with the possibility of external fuel leaks, and the potential for fire and explosion. 3. Run engine to see if problem still exists. If problem has been eliminated, source is located somewhere in boat fuel system back to, and including, the boat fuel tank. If problem still occurs, it is located somewhere in engine fuel system. 1. The electric fuel pumps require an unrestricted, airtight fuel supply. Unscrew the low pressure fuel pump filter and check it for debris. Also check that the filter seals tightly against its fixture and the center mounting threads. Make sure the filter is the correct one for this application. Check threads of filter inlet elbow to ensure a tight seal. If any of these conditions are in doubt, correct them before continuing. //~ CAUTION: 2. Check both fuel pump mounting positions. Pumps must always be located on engine in original factory position. This posi= tion is determined by US Coast Guard regula= tions and must be complied with. Never relocate pump to transom, stringer, fuel tank, or any point other than its original location on the engine. Pressure Testing Fuel System /~ Pump(s) performance can be verified checking pump(s) PSI at specific engine RPM. This test must be performed with engine under load; either running in gear on water, or in gear and connected to a dynamometer. Use a good quality fuel pressure gauge. Follow the gauge manufacturer’s instructions for installation, and ensure that connections are leak free. Refer to GM EFI Diagnostic Manual, Fuel System section to check pump’s operating pressure. New pumps will generally have lower operating pressures. As the gears break in, contact improves and the pump’s pressure will increase slightly. Two other items that would require checking are the screens in each end of the low pressure fuel pump body. This requires removal of the upper elbow and the nower fuel filter adapter. If screens cannot be sufficiently cleaned, replace the fuel pump. The screens are not serviced separately. Checking Boat Fuel System The most common causes of failures in the boat fuel system are due to line restrictions or air entry. Typical restrictions are: ® kinked, bent, or internally swollen fuel lines -fuel lines and/or tank selector valve I.D.’s too small restricted or wrong anti-siphonvalve ® crackedor blocked fuel pick-up or screen inside tank ® blocked tank vent Air entry can occur at any point on the suction side of the fuel system. Air in the fuel system is usually indicated by a humming or squealing noise from the pumps. [~ Fuel pump noise can be caused by air being drawn through the fuel pump gears, but is not always an indicator that something is wrong.Momentarynoise has several causes that are not linked to fuel system fainures: pump(s) may squeal for a short time upon start-up as air is expelled if ambient are high, the temperatures engine compartment will be subjected to hot operating conditions that may create vapor in the fuel lines ¯ a hot engine after shutdown will go into a "hot soak" condition that may produce fuel vapors = the use of ethanol fuel will also aggravate this condition as it is more susceptibleto vapor formation All of these situations are temporary, but may produce vapor that would cause pump(s) noise. Pump(s) noise that is continuous, and/or cannot be attributed to any of these conditions, could be an indicator of fuel system problems VacuumTesting Fuel System CAUTION:This test must be performed with engine under load; either running in gear on water, or in gear and connected to a dynamom eter. Ensure that all fuel line connectionsare leak free. 1. Install VacuumGauge,P/N 390954 (or equiva lent), and 8 in. (20,3 cm) of clear, fuel resistant vinyl hose into the fuel line at the filter bracket inlet. 2. Start engine and allow it to reach normal operating temperature. Run engine at full throttle for at least 2 minutes; observe vacuum gauge reading and check clear hose for air or vapor bubbles. Gauge reading must not exceed 4 in. of mercury (Hg) at any time, and there should be no bubbles visible in the clear hose. Compare observations to the following: [Gauge 1-4 in. Hg. - air bubbles ]J reads present Supply side of fuel system has an air leak. Check points of possible failure as noted under Checking Boat Fuel System. Repair or replace suspect part, then make another vacuum test to verify repair. [Gaugereading exceeds 4 in.Hg. ] Supply side of fuel system has a restriction. Check points of possible failure as noted under 3-30 Fuel Sysleng / DR2065 DR2066 DR214 ReMayOhrnrneter Tests Throughout this section two symbols are used to interpret electrical troubleshooting results. ~] This symbol indicates continuity or very low resistance. ~J This symbol indicates no continuity or very high resistance / To avoid damaging components or troubleshooting equip-DR2149 ment, disconnect the battery cables from the battery and remove the relays before proceeding. 1. Use a continuity light or ohmmeter calibrated on appropriate scale to test continuity. r-3=-I 2. Connect meter leads to relay terminals 87a and 30. ¯ The meter must show continuity. ~___~] 3. Connect meter leads to relay terminals 87 and 30. DR2149 ¯ Th~ meter must show no continuity. r-~] 4. Calibrate an ohmmeter on appropriate scale and connect the leads to relay terminals 85 and 86. ® The meter must show 70 -100 ohms. ~__~=] 5. Connect meter leads to relay terminals 87 and 30. Connect a 12 volt source to relay terminals 85 and 86. ¯ The meter must show continuity. DRZ149 ~=-1 6. Connect meter leads to relay terminals 87a and 30. Connect a 12 volt source to relay terminals 85 and 86. e The meter must show no continuity. 7. Replace relay if your test results vary. DR2149 Engine Fuel System Troubleshooting ENGINE DOES NOT START - iMPROPER STARTING PROCEDURE USED 1. Check the following: fuel level in tank, fue{ tank vent, fuel lines for blockage, tank to pump fuel line for air leaks, fuel filters for blockage, and antFsiphon valve. 2. Check fuel pump for correct pressure/vacuum. 3. Check vapor separator. ENGINE WiLL START WHEN PRIMED - WiLL NOT CONTINUE TO RUN 1. Check fuel supply. 2. Check fuel lines for blockage, air leaks, anti-siphon valve. 3. Check for plugged fuel filters. 4. Check fuel pump for correct pressure/vacuum. 5. Removevapor separator cover; check for dirt, water, varnish deposits; check float level, and float inlet valve operation. ENGINE HARD STARTING, COLD 1. Check fuel pump for correct pressure/vacuum. 2. Check for blockage in fuel lines, air leaks in fuel line from tank to fuel pump. 3. Removevapor separator cover; check float level, inlet valve operation; check for dirt, water, varnish, deposits; check for worn parts, leaking gaskets. ENGINE HARD STARTING, HOT 1. Removevapor separator cover; check float level, float inlet valve operation and condition. 2. Check for fuel line on or near hot surfaces, causing percolating in lines. 3. Check fuel tank vent. ENGINE RUNS ROUGH, LOW SPEED 1. Check for dirt or water in fuel, excessive or insufficient fuel pump pressure. 2. Removevapor separator cover; check for proper float level, internal blockage, defective parts, and varnish deposits in passages. 3. Check other systems; intake manifold for vacuum leaks, sticking valves, overheating, etc. 4. Check setting and operation of throttle plate opening. (continued on next page) FuetSys/eng 3-32 Engine Fuel System Troubleshooting (cont.) ENGINE RUNS ROUGH, HiGH SPEED ’1.Check for sufficient fuel in tank, blocked tank vent, anti-siphon valve, proper fuel. 2. Check for water or dirt in fuel; check for correct fuel pump pressure/vacuum; check for blockage or air leaks in fuel line. 3. Removevapor separator cover; check float level, float inlet valve operation, internal blockage, varnish, and worn parts. 4. Check for plugged fuel filters° ENGINE DiES (ON INITIAL ACCELERATION) OR HAS ACCELERATION FLAT SPOT 1. Check fuel line,,; for fuel leaks or partially plugged tank vent. 2. Check for water or dirt in fuel; check fuel pump for correct pressure/vacuum. 3. Removevapor separator cover; check for dirt and water; check float level and float inlet valve for operation; check for varnish in passages, worn parts. ENGINE WiLL NOT TURN RECOMMENDED RPM ’1.Check throttle tinkage adjustments to be sure throttle opens fully. ;Z.Check fuel lines for leaks; check fuel pump for correct pressure/vacuum. 3. Removevapor separator cover; check for dirt and water; ~;heck float level and float inlet valve for operation; check for varnish in passages, worn parts. Check boat for proper trim and propeller; check hull for marine growth. 5., Check ignition system components. 6. Check engine and drive unit for partial seizure. 7. Check fuel tank, for plugged vent; check pickup tube for w]cuum leaks. 8. Check for plugged fuel filters. 9. Check for full opening of throttle. 10. Check exhaust system for restrictions. ’| 1= Check lower gearcase and propeller for exhaust restrictions. 12. Check for restricted air intake. Torque Specifications Circuit Breaker ................. 20-25 in. Ibs. (2,3-2,8 N.m) Fuel Pressure Regulator Outlet Line ...... 13 ft. Ibs. (17,5 N.m) Circuit Breaker ................. 20-25 in. Ibs. (2,3-2,8 N.m) Engine Control Module ........... 88-124 in. Ibs. (10-14 N.m) Fuen Rail Screws ..................... 89 in. Ibs. (10 N.m) Fuet Rail Stud/Nut ..................... 18 ft. Ibs. (25 N.m) Idle Air Control Valve ................. 28 in. Ibs. (3,2 N.m) Intake Plenum ........................ 15 ft. nbs. (20 N.m) Manifold Absolute Pressure Sensor ....... 18 ft. lbs. (24 N.m) Throttle Body Assembly ............... 89 in. Jbs. (10 N.m) Throttle Position Sensor ................ 18 in. Ibs. (2 N-m) Upper Plenum ....................... 10 ft. Ibs. (14 N.m) Engine Coolant Temperature Sender ..... 108 in. Ibs. (12 N.m) Intake Air Temperature Sensor ........... 11 ft. Ibs. (15 N.m) Knock Sensor ........................ 14 ft. Ibs. (19 N.m) 3-34 FueiSys,’eng Section 4 GM MFi Fuel System 7.4GSi and 8.2 GSi Models Table of Contents Fuel System Component Replacement .... 4-10 Intake Air Temperature Sensor ............ 4=6 Circuit Breaker ........................ 4=27 Knock Sensor .......................... 4-8 Electric Fuel Pump (High Pressure) ....... 4-25 Knock Sensor Module ................... 4-9 Electric Fuel Pump (Low Pressure) ....... 4=20 Manifold Absolute Pressure Sensor ........ 4-4 Engine Control Module .................. 4-3 Relay ................................. 4-27@ Engine Coolant Temperature Sensor ....... 4-4 Relay Ollmmeter Tests .................. 4=31 Filter Bracket .......................... 4-28 Sensors and Control Replacement ......... 4-3 Flame Arrestor ........................ 4=11 Throttle Body Assembly ................. 4-12 Fuel Control Service .................... 440 Throttte Position Sensor ................. 4-5 Fuel Injectors .......................... 4-19 TorqueSpecifications ................... 4-34 Fuel Pressure Regulator Assembly ....... 4=18 Troubleshooting Fuel Pressure Relief Procedure .......... 4-11 Checking Boat Fuel System ........... 4-30 Fuel Rail Assembly ..................... 4=16 Engine Fuel System .................. 4-32 Fuel Reservoir ......................... 4-23 Electric Pump(s) ...................... 4=29 General Information ..................... 4-3 Vacuu=mTesting Fuel System .......... 4=30 IAC Valve/Coolant Cover Assembly ....... 44 3 Upper intake Plenum ................... 4-14 idle Air Control Valve .................... 4-7 Use this section for replacement or repair of GM MFI components, Read and comply with all notes and safety warnings while performing service procedures to avoid personal injury or damage to components, if a fastener needs to be replaced, use the correct part number fastener for that application. A fastener of equansize and strength (or stronger) may be used if the correct part numi~.~r is not available. Safety Warnings Before working on any part of the fuel system, read the section called Safety at the end of this manual. The original mounting, support and routing of the fuel system parts conform with U. S. Coast Guard requirements, it is important to maintain the original mounting, support and routing after servicing the fuel system. Gasoline is extremely flammable and highly expJosive under certain conditions. Ensure good ventilation. Do not smoke or allow open flames or sparks near fuel system or in engine compartment while servicing. When making instrument attachments or working around an engine being run or cranked, use extreme care to avoid getting hands, fingers or clothing caught in the alternator and water pump belts, pulleys and other moving parts. Owatonna Tool Co. EFI Fuel Pressure Gauge ....................... OTC-7211 Adaptor ................................... 0TC-7272 4-2 FuelSys/eng General Information -[he ECM and all EFI sensors are sensitive electronic components. Observe the following cautions when servicing them: Z~ o Verify the ignition switch is in the "OFF" position, and remove the negative battery cable from the battery, ¯ DO NOT soak components in any liquid cleaner or solvent; this will damage them. ® Handle components carefully; any damage will affect 37544 proper operation of the EFI system. ® Make sure new components have the same part number as old ones; this will ensure proper engine performance. Sensors and Control Replacement Engine Control Nlodule (EClVl) Removal 37545 [~ When replacing the ECM, the ignition must be "OFF" and disconnect the battery before disconnecting or reconnecting the ECM "Jl" and "J2" connectors to prevent damage to the ECM. To prevent possible electrostatic discharge damage to the ECM, DO NOT touch the connector pins. The ECM is an ePectrical component that can easily be damaged by static electricity. Do not soak the ECM in any liquid cleaner or solvent, as damage may result. ©. ©. E~ 1. Remove the "Jl" @ and "J2" ® connectors from the ECM 37547 E~ 2. Unscrew four ECM mounting bolts @. Remove the ECM from the mounting bracket. installation r=~ 1. Attach the new ECM to the mounting bracket and secure with four bolts. Tighten the bolts @ to 88-124 in. Ibs. (10-14 N.rn). E=4~ 2. Connect the "Jl" ® and "J2" ® connectors to the ECM. 37878 37551 37552 Engine Cooaant Temperature (ECT) Sensor Removal [~ 1. Remove the ECT sensor electrical connector@. E~] 2. Unscrew the ECT sensor ® from the intake manifold. Installation 1. Coat the ECT sensor threads with pipe sealant with Teflon, 37554 [~ 2. Install the ECT sensor ® into the intake manifold. Tighten the sensor to 108 in. lb. (12 N-m). [~ 3. Attach the ECT sensor electrical connector (~. Manifold Absolute Pressure(MAP) Sensor Removal [~ 1. Remove the MAP sensor electrical connector @. DE] ~ 2. Unscrew the two screws @ secudng the MAP sensor @. to the upper intake manifold. Remove the MAP sensor and seal ®. 37555 37556 4-4 FuelSys/eng Fuel Sys/eng 37557 37559 Installation E=8-~ 1. Place a new seal ® on the MAP sensor. E-9.~ 2. Install the MAP sensor onto the upper intake manifold and secure with two screws @. Tighten the screws to 44-62 in. Ibs. (!5-7 N m). [~1=~ 3. Attach the MAP sensor electrical connector ©. 37561 l"hrottle Position (TP) Sensor Removal 1. Remove the flame arrestor from the throttle body following instructions found elsewhere in this section. ~_~ 2. Remove the TP sensor eDectrical connector @. r~ [~ 3. Unscrew the two screws ® securing the TP sensor to tile throttle body. Remove the TP sensor and seal O. 37562 37563 Installation If replacing the TP sensor, use the new screws that are supplied with the TP sensor service package. [~ 1. Place the TP sensor seat (~) over the throttle shaft, [~ 2. Verify that the throttle plates are closed, Position the TP sensor on the throttle shaft and align the screw holes. J-~ 3. Install the two retaining screws ® and tighten to 18 in. Ibs. (2,0 N.m). [~ 4. Attach the TP sensor electrical connector ©. Z~ 5. Install the flame arrestor foltowing instructions found etsewhere in this section. intake Air Temperature (IAT) Sensor Removal [~ 1. Remove iAT sensor electrical connector @. 37564 37565 37576 37577 Z~ FueISys;eng Safety ReUated 4-6 37581 37579 37580 [~ 2. Unscrew IA’I" sensor ~) from intake manifold. Installation 1. Coat the threads of the IAT sensor with pipe sealant with Teflon. 2. Screw the IAT sensor (~ into the intake manifold and tighten to 11 ft. lb. (15,0 N-rn). [~ 3. Attach the IAT sensor electrical connector @. Idle Air Control (IAC) Valve 37566 Removal 1. Remove body following instructions flame arrestor from throttle found elsewhere in this section. ~] 2. Remove the IAC valve electrical connector ®. [~] [~ 3. Remove the two screws @ securing the IAC valve to the throttle body. Remove the IAC valve and discard the O-ring ®. if an IAC valve has been in service, DO NOT push or pull 37567 on an IAC valve pintle. The force required to move the pintle may damagethe threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent. This will damage the valve:. 37568 Cleaning and inspection Both original and replacement IAC valves have a special ® ® factory Bocking compound applied to the screw threads. If the valve removed from the throttle body is being reinstalled, do not remove the thread locking compound that may be on the threads. Clean the IAC valve O-ring sealing surface, pintRe valve seat, and air passage. Use carburetor cleaner to remove carbon deposits. DO NOT use a cleaner that contains methyl ethyl ketone, an extremely strong solvent, and not necessary for this type of deposit. Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft. DR5524 InstaBation If installing a new IAC valve, be sure to replace the old valve with an identical part. IAC valve pintle shape and diameter are designed for the specific application. [~ 1. If installing a new IAC valve, measure the distance between the tip of the valve pintle @ and the mounting surface ®. If greater than 1.102 in. (28 mm), use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the new valve. r 37569 it 2= Lightly lubricate on the IAC valve. a new O-ring © with engine oil and place ~] 3. Install the IAC valve into the throttle body and secure with two screws @. Tighten the screws to 28 in. lbs. (3,2 N.m). ~] 4. Attach the IAC valve electrical connector ~. /~ 5. Install the fname arrestor elsewhere in this section. following instructions found 37570 6. Reset IAC valve pintDe position as follows: e Start and run engine for 30 seconds. ¯ Turn ignition "OFF" for 10 seconds. ¯ Restart engine and check for proper idle operation. Knock Sensor (KS) Removal [~ 1. Remove knock sensor electrical connector (~). 37571 Z~ Safety Related 4-8 FuelSys,’eng 37573 37574. 37575 [~_-"] 2. Unscrew the knock sensor @ from the engine block. Installation ~-ot~ Install the knock sensor in the same location as the old one. Makesure the threads are clean. If installing the knock sensor in a water jacket, coat the threads with pipe sealant with Teflon. 1.Thread the knock sensor @ into the engine block and to 11-16 ft. lb. (15-22 N-m). 37569 [~ 2. Attach the knock sensor electrical connector ®. Knock Sensor (KS) Module Rernova! [~ 1. Remove the knock sensor module electrical connector ®. 2. Removethe two screws (D securing the knock sensor module to the engine. Remove the module. installation 37597 ’t~ 1. Install the knock sensor module on the engine and secure; with two screws O. Tighten the screws securely. ~ 2. Attach the knock sensor module electrical connector @ to the module. 37598 Fuel System Component Replacement Safety Warnings To reduce the risk of fire and personal injury, relieve the fuel system pressure before servicing any fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. To reduce the chance of personal injury, cover the fuel line fittings with a shop towel before disconnecting to catch any fuel that may leak out. Place thetowel in an approved container when service is completed. Fuel Control Service The following is general information required when working on the fuel system: ® Always keep a dry chemical fire extinguisher near the work area. ¯ Fuel pipe fittings require new O-rings for reassembly. o DO NOT replace fuel pipe with fuel hose. e Always bleed off fuel pressure before servicing any fuel system component. ¯ Do not do any repairs on the fuel system until you have read the instructions and checked the figures relating to the repairs. ® Observe all safety warnings and notes. Safety Related 4-10 FuelSys/eng Fuel Pressure Relief Procedure ~ Refer to the special tool manufacturer’s warnings, and cautions before proceeding, Z~ 1. Disconnect the negative battery cable from the battery to avoid possible fuel discharge if an accidental attempt is made to star[ the engine. 2. Remove protective cap @ from the fuel pressure connec.tor assembly. ~-] [~] Z~ 3. Connect Owatonna Tool Co. Adaptor O7C-7272 ® and EFI Fuel Pressure Gauge OTC-7211 © to the fuel pressure connector assembly ~. Wrap a shop towel around the fitting! while connecting the gauge to avoid spilling fuel. Z~ 4. Place bleed hose into an approved container. Open the valve to bleed fuel system pressure into the container. Fuel connections are now ready for servicing. Drain any fuel remain ing in the gauge into the container, then remove the gauge assembly. Flame Arrestor Removal E~ 1. Remove hoses (~) from the flame arrestor. Remove flame arrestor retaining nut and washer ®. Remove the arrestor from the throttle body. Remove the gasket @ from the arrestor. 37649 37600 37602 37603 FuelSys,’eng ~ Safety Related I 3758E 37604 37588 inspection inspect the flame arrestor element for dust, dirt, water, or damage. Inspect the flame arrestor gasket for cuts and tears. Clean or replace as necessary. installation The flame arrestor may be baffled for correct air distribution. Et must be installed as it was taken off. 37589 [~ 1. Place the gasket (~ on the flame arrestor. 2. Place the flame arrestor on the throttJe body. Secure the flame arrestor with retaining nut and washer ®. Tighten the nut securely. [~ 3. Attach hoses © to the flame arrestor. Throttle Body Assembly The throttle body assembly repair procedures cover component 37590 replacement with the unit on the engine. However, thrott}e body replacement requires that the complete unit be removed from the engine. Removal 1. Remove flame arrestor from throttle body folJowing instructions found elsewhere in this section. [~ 2. Remove the electrical connectors from the TP sensor (~) and ~AC valve (~. 37591 [~ 3. Remove the nut (~) securing the throttle link @ to the throttle body arm, then remove the link. 4. Remove the four screws ® securing the throttle body to the upper intake plenum. Remove the throttle body assembly and flange gasket. Discard the gasket. Z~ Safety Related 4-12 FuelSys,reng Cleaning and Inspectien ~o=t~ DO NOT soak the throttle body in a cold immersion type cleaner. The throttle valves have a factory applied sealing compound (DAG) material applied to the outside edge of each valve and throttle bore to prevent air bypass at closed throttle. Strong solvents or brushing will removethe material. To clean the throttle body following disassembJy,use a spray type cleaner such as carburetor and choke cleaner. Clean all gasket surfaces of old gasket material. Use care when removing the old material as sharp tools may damage the aluminum sealing surfaces. Instainatien 1. install the throttle body assembly onto the upper intake ple num, using a new flange gasket. Secure the assembly with four screws. Tighten the screws to 11 ft. lb. (15 N-m). 2. Checkto see that the throttle lever is free. Move the throttle lever to full throttle and rebase. The throttle should snap back to the cbsed position° If it doesn’t, remove the throttle body assembly and check for a binding thLrottle shaft. ~] ~ 3. Attach the throttle link @ to the throttle body and secure with nut ®. [~ 4. Attach the electrical connectors to the TP sensor @ and IAC valve ~. 5. install the flame arrestor following instructions found elsewhere:In this section. Z~6. Connect the negative battery cable to the battery. Tighten nut securely. 7. R, eset IAC valve pintle position as follows: ¯ Start and run engine for 30 seconds. ¯ Turn ignition "OFF" for 10 seconds. ¯ Restart engine and check for proper idle operation. idle Air Control Valve/Coolant Cover Assembly Removal and Disassembly 1. Removethrottle body from upper intake plenum following instructions found elsewhere in this section. 37623 37624 37625 2. Remove the IAC valve assembly following instructions found elsewhere in this section. [~ 3. Remove the coolant cover screws° Remove the cooDant cover (~ and discard the gasket (~. Cleaning and inspection 1. Clean the gasket sealing surfaces. 2. Inspect the gasket sealing surfaces for corrosion or damage that would cause a leak. Replace the cover assembly or the throttle body if necessary. Assembly and installation 1. Place the cover assembly with a new cover gasket onto the throttKe body. Secure the cover with the cover screws ©. Tighten the screws to 28 in. Ibs. (3,2 N.ml. 2. Install the IAC valve following instructions found elsewhere in this section. 3. Unstali the throttle body assembly onto the upper intake plenum following the instructions found elsewhere in this section. Upper Intake Plenum Removal ~] 1. Remove hoses @ from bottom of flame arrestor. 2. Removethe throttle cable from the throttle body bellcrank. 3. Removethe eJectrical connectors from the ECM "’Jl" and "J2", KS module, TP sensor, IAC valve, MAP sensor, and IAT sensor. See the appropriate sections in this manual for component location. [~ 4. Remove the vacuum hose (~ to the fuel pressure regulator ®. E~ 5. Remove vapor hose (~ to purse limiter ®. E~ 6. Remove the plenum retaining bolts (~). Remove the upper intake plenum. Remove and discard the eight O-ring seals. Make a note of the throttle bracket (~ and fuel line bracket position ® for reinstallation. 37621 37622 37603 37626 37871 4-14 F~e~Sy~oo~ ~_~.et~ When handlhlg the intake plenum, be careful not to damage the plenum-to-lower intake and throttle body surfaces. After the plenum has been removed, covers must be installed over the exposed lower intake manifold ports to prevent any foreign material from entering the engine and causing serious damage. 7.If the plenum is to be replaced, remove all componentsfollowing the instructions found elsewhere in this section. Cleaning and Inspection Whencleaning the plenum, be careful, because the plenum is made of aluminum. DO NOT gouge the gasket or O-ring seal surfaces or use a power wire brush. 1. Removeall old gasket material from gasket surfaces. Clean all O- ring grooves. 2. Clean the interior of the plenum of any sludge or oil build up. Use a spray type cleaner such as carburetor and choke cleaner or equivalent that does not contain methyl ethyl ketone. MEK is an extremely strong solvent and is not necessary for this type of deposit. :H;~’~M~N,T DO NOT soak intake plenum in any liquid cleaning solvent if any components are still attached, as damage to the components may result. 3. Inspect the entire plenum mating surface for burrs, porosity (small holes in the casting due to manufacturing flaws), and cracks caused by handling. Installation [~ 1. Coat the eight O-ring seals (D with a light grease, install the O-ring ring seals in the lower intake O-ring grooves. E~] 2. Place the plenum on top of the lower intake manifold. Be careful not to move the O-ring seals out of their grooves. E~] 3. Lightly coat the threads and shafts of the retaining bolts with Lubriplate 777 or equivalent. Install the bolts into the plenum. Tighten in several steps, in the sequence shown, to 124 in. lb. (14 N-m). 4. Connect vapor hose @ to pulse limiter ® and secure with clamp @. 5. Attach the electrical connectors to the IAT sensor, MAP sensor, JAC ,valve, TP sensor, KS module, and ECM "J2" and "J1" connection points. See the appropriate section for component location. 37627 37628 37635 DR5525 [~] 6. Connect the vacuum hose @ to the nippRe on the upper intake manifold. Z~7. Connect the throttle cable to the throttle body bellcrank and secure with fiat washer and cotter pin. Check for proper throttle operation and adjustment. Fuel Rail Assembly Removal and Disassembly The fuel rails should be removed as an assembly with the injectors attached. Use care in removing the fuel rail assemblyto prevent damage to the electricaJ connector terminals and injector spray tips. Whenremoved, support the rail to avoid damaging its components.Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during servicing. Z~ WARNING: 1. Wear Safety Glasses. Before removing the fuel rail assembly, clean the assembly with a spray type engine cleaner. Clean the area where the injectors fit into the intake manifold. Use compressedair to blow dirt from around the injectors before removing them. //~k 2. Relieve fuel system pressure following the instructions found elsewhere in this section, 3. Removethe upper intake plenum following instructions found eDsewhere in this section. E~] [~/~k 4. Disconnect the fuel return line ® and high pressure fuel line @. Be ready to catchanyfuel that remains in the lines. E~ [~ 5. cut the tie straps @ securing the wiring harness to the fuel rail. Press on the clip (~ then remove the electrical connectors ® from the injectors. Move the wiring harness out of the way. 6. Removefour screws @ securing the fuen rail to the intake manifold. Remove the fuel rail and injectors as an assembly. 37636 37611 37610 37612 FuelSy .... g 4-16 7. Remove the injectors from the fuel rails following the instructions found elsewhere in this section. Cleaning and inspection 1+ C, lean the fuel rail assemblywith a spray type cleaner. DO NOT soak the fuet rails in liquid cleaning solvent+ 2 Rnspect injector and fuel line connector bores for nicks, burrs, or corrosion. Ctean lightly with emery cloth in a radial motion. 3. Inspect the O-ring seal grooves on the fuel line connectors, pressure regulator fittings, and injectors. Assemblyand InstaBation [~o_t~ To prevent leakage and risk of fire, all O-ring seals need 1o be replaced to ensure proper sealing. 1. Install the fuel injectors with new O-ring seals following the instructions found elsewhere in this section. E~ 2. InstalJ the fuel rail and injectors as an assembly onto the lower intake manifold. If the injectors are lined up properly, they will slide into place with ease. Push gently and evenly on the fuel rail to set the injectors all the way into their bores. Secure the fuel rails with the mounting screws @. Tighten the screws to 88 in. lb. (110 N-m). 3. Attach the injector electrical connectors ® to the injectors. Secure the wiring harness in place with tie straps @. DE]~ 4. Attach the high pressure fuel line @ and return line ®. Tighten the fittings to 13 ft. lb. (17,5 N-m). 5. InstaFI the upper inlake plenum following the instructions found elsewherein this section. ~8. Connect the negative battery cable to the battery. Tighten nut securely. 7. Bleed the fuel system by cycling the ignition key "ON" and "OFF" a few times with the engine "OFF." ~8. Turn the ignition key to the "ON" position for two seconds, then "OFF" for ten seconds.Again, turn the key to the "ON"position and check for fuel leaks. Repair any leaks found before attempting to, run the engine. 37669 37670+ 37671 37672 Fuel Pressure Regulator Assembly Removal ~The fuel pressure regulator assembly is serviced as a complete assembly only. Z~ 1. Verify the ignition switch is in the "’OFF" position. Remove the negative battery cable from the battery. 2. Relieve the fuel system pressure by referring to Fuel Pressure Relief Procedure found elsewhere in this section. 3. Remove the upper intake plenum and fuel rail by referring to instructions found elsewhere in this section. 4. Remove the vacuum hose ® from the regulator. [~ 5. Remove fuel return line ® from regulator. Use a back up wrench to hold the regulator to keep it from turning and possible damage. [~ 6. Remove regulator mounting screw ©. Remove regulator from fuel rail and discard O-ring @. inspection The fuel input port of the pressure regulator may contain a filter screen. Inspect the screen for dirt and debris. If dirty, use a pick to remove the filter screen and discard. Replace it with a new one. installation r~ 1. Lubricate a new fuel pressure regulator O-ring @ with clean engine oil and install it on the regulator. 2. Push the regulator into the fuel rail and install the regulator mounting screw. Tighten the screw to 84 in. Ibs. (9,5 N.m). 37615 37617 37618 Z~ Safety Related FuelSysieng 4-18 ~ 3. Connect tile outlet line ® to the regulator. Tighten the fitting finger tight only. Tighten the outJet Erie nut (~ to 13 ft. Ibs. (17,5 N.m), Use a back up wrench to keep the regulator from turning and possible damage, 4. Connect the vacuum hose (~ to the regulator. Z~ 5. Connect the negative battery cable to the battery. Tighten nut securely. 6. Turn the ignition switch to the "ON" position for two seconds, then to the "OFF" position for ten seconds. Turn the ignition switch back to the "ON" position and check for fuel leaks, Repair any leaks before attempting to run the engine. Fuel injectors Removal Use care in removing the injectors to prevent damage to the injector electrical connector pins or the spray tips. The fuel injector is serviced as a complete assembly only. Since it is an electrical component, DO NOT immerse it in any cleaner. Z~ 1. Relieve the fuel system pressure by referring to Fuel Pressure Relief Procedure found elsewhere in this section. 2. Remove the upper intake plenum and fuel rail following the instructions found elsewhere in this section. [~ 3. Release the injectors (~ by sliding the injector clips to the side. Remove the injectors from the fuel rail. Removeand discard both O-ring seals ® from the ends of the injectors. Removethe injector (:lips @ from the fuel rail. Cleaning and inspection 1. Inspect injector bores in fuel rail and intake manifold for nicks, burrs, or corrosion damage, if severe, replace the damaged components. Clean lightly with emery cloth in a radial motion. 2. Inspect injector O-ring seal grooves for nicks, burrs, or corro.sion. Replace the injector if damaged. Clean the injector with spray cleaner and wipe clean with a lint free cloth. 3. DO NOT use abrasive materials or wire brushes on injectors. They are plated with an anti-corrosion material° ~When ordering individual replacement fuel in-jectors, be sure to order the identical part number that is inscribed on the old injector. Verify the new injector part number matches the old part number before installing the new injector. 37564 37665 ® ®@ 37666 FuelSvs/eng ~ Safety Related 4-19 37667 37668 Installation E~ 1. Lubricate the new iniector O-ring seals ~ with engine oil and insta[] them on the injectors. Install a new injector clip (~) onto the injectors. [~] 2. Push the injectors onto the fuel rail with the electrical connector facing forward. Snap the retainer clip into the grooves on the fuel rail. 3. Install the fuel rail and upper intake plenum following the 30639 instructions found elsewhere in this section. Electric Fuel Pump -Low Pressure Removal Z~ This pump has been designed to meet U.S. Coast Guard fuel systems regulations for marine use. Do not substitute other brands or models that may be similar in appearance. Use of a substitute pump could result in leakage of fuel or fumes, and causefire and explosion. 30630 [~ Z~ 1. Disconnect boat fuel supply line at fuel filter and install plug ©. [~ [~ 2. Cut tie strap @ holding electrical leads to pump. Puff connector ~ off pump suppressor. E~ 3. using two wrenches, one holding pump elbow and other on fuel line nut, unscrew fuel line (~ at pump and pull line out of elbow. [~ 4. Hold the pump end cap with an open end wrench @, and 30647 loosen the ho~d down lock nut ~ below the elbow. Unscrew the elbow. Z~ if pump end cap is not held when removing nut, end cap may rotate and damageinternal O=ring that seals pump against external fuel leakage. Z~ Safety Related 4-20 FuelSysleng 5. Remove two filter bracket bolts (~. Slide pump out of grommet @ in upper bracket after last bolt is removed. Z~ Fuel filter may contain fuel; be careful not to spill it. [~ 6. To remove fuel filter and bracket from pump, hold lower pump end cap ® with an open end wrench, and unscrew adapter at base of pump. If pump end cap is not held when removing adapter, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. Installation 1. Place a new O-ring (~ on the filter bracket adaptor and position it against he>(. Do not nick or cut O-ring on threads. Z~ This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. ~] 2. Screw filter bracket assembly into pump. Hold Iowe~r pump end cap ®with an open end wrench and tighten adaptor to 8-10 ft. Ibs. (11-14 N.m). Z~ if pump end cap is not held when installing adapter, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. 3. Slide pump up through grommet @ and install two boats ~. Tighten bolts to 20-25 ft. Ibs. (27-34 N.m). 4. Before installh~g upper eabow, turn nut ~ up against head of eUbow. Slide washer and O-ring ~) up against nut. Do not nick or cut O-ring on threads. This O-ring is made of a special fuel resistant material Substitution of parts of unknown quality could result in a fuel leak, and the possib#ity of fire and explosion. 30628 30635 30626 FuelSys/eng ~ Safety Related 4-21 ~ 5. Screw elbow ala the way into pump outlet, then back it off until it aligns with the fuel line. Attach fuel line, and while holding elbow, tighten line fitting securely. [~] Z~ 6. Screw elbow lock nut (~ down against pump outlet. Hold pump end cap ® with an open end wrench and tighten nut to 60-84 in. Ibs. (6,8-9,5 N.m). if pump end cap is not held when tightening nut, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. 7. Align connector tabs © and push connector onto pump suppressoruntil it chicks into place. 8. Install tie strap @ to hold electrical leads against pump body. /~k 9. Connect boat fuel line. Attach negative cable to the battery. Tighten nut securely. Run engine and check for fuel leaks. 30631 30621 30639 30641 Z~ Safety Related 4-22 FueESys/eng Fuel Reservoir Removal EE~ 1. Loosen hose clamps (~ and remove water inlet hose and outlet hose @ from fuel reservoir. ~---’J 2. Cut the tie strap, then unplug the electrical connector ~> from the high pressure fuel pump. I~t 3. Loosen clamp (~ and remove reservoir vent hose 0 from reservoir. r-El 4. Remove low pressure inlet line ®, high pressure outlet line ©, and fuel return line ~ from the reservoir. EE~] 5. Loosen clamp ® and remove cooling outOet hose @. 37638 37639 37641 [~ 6. Remove two screws (~ securing reservoir to the engine. Remove the reservoir. Float Level Setting 1. Unscrew the reservoir cover screws and remove the cover. Discard the cover gasket. [~ 2. Turn the reservoir cover over to aliow the float to seat the float needle. [~ 3. Measure from the top of the float to the inside surface of the cover. Adjust the float to a 3/16 inch (4,76 mm) measurement by lightly bending the adjustment tab ©. After setting the float level, ensure free float movementon the float pivot pin. [~E] Do not force the viton tipped float needie against the needle seat or the resilient needle tip may be damaged. 4. Place a new cover gasket on top of the reservoir. Install the cover and secure with eight screws. Tighten the screws to 25-35 in. Ibs. (2,8-4,0 N.m). Installation [~ 3. Connect the fuel reservoir coolant inlet nippUe to the inlet hose (~. Install the fuel reservoir and secure with two screws (~. Tighten the screws to 24-38 ft. Ibs. (38-49 N.m). [3~ 2. Attach thermostat housing cooling hose ~ to reservoir and secure with clamp ®. EEl ,~ 3. Attach fuel rail high pressure fuel line @, fuel return line ®, and the low pressure fuel line (~ to fuel reservoir. Tighten all line fittings to 10-12 ft. Ibs. (13,6-16,3 N.rn). Safety Related 4-24 ~ 4. Attach upper intake manifold vent hose @ to reservoir. Secure with clamp ® te prevent leakage of fuel fumes. 5. Connect two .- wire connector O to fuel pump. Secure with tie strap @, ~8__-] 6. Attach outlet ® cooling hoses to the reservoir. Secure the inlet and outlet hoses with hose clamps @. 7. Energize fuel pumpsand check for leaks. Electric Fuel Pump -High Pressure Removal ~ot~] Pump service may be done with the reservoir either on or off the engine. 1. Removethe high pressure fuel line to the throttle body. ~:] [~ 2. Make note of the position of the elbow, then back off the elbow lock nut ~). Unscrew the elbow from the pump. [~_-] 3. Unscrew the two screws @ securing the end bracket ® to the reservoir. Remove the bracket from the pump. 37850 37651 37852 ® FueISys’eng ~ Safety Related 4. Unscrew the banjo nut from the end of the pump and remove the pump. Discard all O-rings. Pump Instamlation [~ 1. Lubricate one new small O-ring @ with engine oil and place it on the threaded end of the elbow. Lubricate one large O-ring ® with engine oil. Place it on the banjo nut in the O-ring groove closest to the hex head. Z~ These O-rings are made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. [~ 2. Install banjo nut © into hole in reservoir cover. Lubricate a second new large O-ring ® with engine oil. Place the O-ring on the threaded end of the banjo nut. Z~ This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. [~ ~ 3. Thread the banjo nut into the high pressure fuel ° pump. Position the pump at a 45 angle. Hold pump end cap with a ,wrench, and tighten the banjo nut to 18-22 ft. Ibs. (24,4-29,8 N.m). ff pump end cap is not held when installing banjo nut, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. E~ 4. Place fuel pump support bracket @ over the end of the pump. Secure the bracket to the reservoir cover with two screws ~. Tighten the screws to 25-35 in. Ibs. (2,8-4,0 N.m). [~ E~ z~ 5. Attach the elbow to the end ofthe pump. Position the elbow as noted in the removal procedure. Screw the elbow lock nut ® down against the pump outlet. Hold the elbow @with an open end wrench and tighten nutto 80-84 in. Ibs. (6,8-9,5 N.m). Z~ if elbow is not held when tightening nut, elbow may rotate and damage internal O-ring that seals pump against external fuel leakage. 32122 ®® 37646 32121 32191 Z~ Safety Related 4-26 FuelSys/eng Circuit Breaker 8. Volvo Penta’s EFI GM engines have four circuit breakers as pro tection devices: A 12.5 amp circuit breaker protects the fuel injector relay and ECM A 50 amp circuit breaker protects the trim/tilt motor ¯ A 60 amp circuit breaker protects the main engine harness @ A 20 amp circuit breaker protects the fuel pump reRay and 37644 circuit Models have a 10 amp circuit breaker, located on the trim/tilt pumpto protect the pump relay. If this component the ECM or circuit fails, will not store a service code in the memory. Circuit Breaker Replacement 1. Makea note of the lead position, then remove all the leads from circuit breaker.Remove circuit the screws and nuts, and lift breaker out of bracket. 2. Install new circuit breaker and secure with screws and nuts. 37645 Tighten screws to 20-25 in. lb. (2,3-2,8 N-m). 3. Attach the leads to their original positions on the circuit breaker and secure with the nuts. Tighten the nuts to 20-25 in. lb. (2,3-2,8 N- m). Coat the termina!s with liquid neoprene. Relay [~ Replace the relay by pulling it off its mounting bracket, install the relay by aligning the terminals of the relay with the bracket. Push the relay in until it seats. DR4640 37872 4-27 Filter Bracket The electric fuel pump filter has an internal seal around the fuel exit point that prevents leakage and drain back. Do not substitute other filters that may be simiaar in appearance. To replace filter canister, refer to Fuel Filter Replacement in this section. elsewhere 1. Removefuel pump and filter bracket assembly from mounting bracket. 2. Unscrewfuel inlet elbow and save for installation on new bracket. 3. Clamp filter bracket in a vise and unscrew adapter and pump assembly. Discard bracket. 4. Thoroughly clean adapter threads to remove old sealer, then apply pipe sealant with Teflon to the threads. 5. Clamp new bracket in a vise. Screw in adapter and pump assembly, and tighten to at least 10 ft. lb. (14 N-m). Continue tightening adapter to achieve proper pump/bracket directional alignment. Do not exceed 32 ft. lb. (43 N-m) torque. 6. Thoroughlyclean threads of inlet elbow to remove old sealer, then apply pipe sealant with Teflon to the threads. Screw in elbow and tighten to at least 12 ft. lb. (16 N-m). Continue tightening elbow achieve proper directional alignment. Do not exceed 32 ft. lb. (43 N-m) torque. 7. install fuel pump and filter bracket assembly in mounting bracket. ~8. Run engine and check for fuel leaks. 4-28 Fuel Sys/eng TroubleshootingElectric Pump(s) Checking Engine Fuel System Start by verifying the pumps are receiving a mini mumof 12.0 + 1 volt. Removethe connector from each pump suppresser. Disable ignition to prevent engine from running, then crank engine and check yellow~greenlead with a voltmeter. Turn key off, then check connector black lead with an ohmmeter for a good ground, tf voltage is not as specified, or ground path is suspect, check: ° relay and bracket circuit breaker = wiring related to all of the above Ensure all items are functioning correctly before proceeding. As voltage to the pump drops, so will its output capability. 2. Once it has been established that the pumps are receiving proper voltage, separate the engine fuel system from the boat’s fuel system. Disconnect the supply line at the pump’s fuel filter, and place a pick-up hose in a vented fuel container. The pick-up hose must have a minimum I.D. of 3/8 in. Z ..~ WARNING Do not connect engine fuel system to any supply system having a pressure producing device such as an outboard fuel tank with primer bulb, or another electric fuel pump located elsewhere in the boat or at the fuel tank. The pumps are sensitive to additional fuel pressure, and will add this to its own output. The result will be a continually flooding fuel reservoir with the possibility of external fuel leaks, and the potential for fire and explosion. 3. Run engine to see if problem still exists. If problem has been eliminated, source is located somewherein boat fuel system back to, and including, the boat fuel tank. If problem it is still occurs, located somewhere iin engine fuel system. 1. The electric fuel pumps require an unrestricted, airtight fuel supply. Unscrew the low pressure fuel pumpfilter and check it for debris. Also check that the filter seals tightly against its fixture and the center mounting threads. Make sure the filter is the correct one for this application. Check threads of filter inlet elbow to ensure a tight seat. If any of these conditions are in doubt, correct them before continuing. /~ CAUTION" 2. Check both fuel pump mounting positions. Pumps must always be located on engine in original factory position. This position is determined by US Coast Guard regulations and must be complied with. Never relocate pump to transom, stringer, fuel tank, or any point other than its original location on the engine. Pressure Testing FueO System J~ Pump(s) performance can be verified by checking pump(s) PSi at specific engine RPM. This test must be performed with engine under load; either running in gear on water, or in gear and connected to a dynamometer. Use a good quality fuel pressure gauge. Follow the gauge manufacturer’sinstructions for installation, and ensure that connections are leak free. Refer to GM EFI Diagnostic Manual, Fuel System section to check pump’s operating pressure. New pumps will generally have lower operating pressures. As the gears break in, contact improves and the pump’s pressure will increase slightly. 4-29 Two other items that would require checking are the All of these situations are temporary, but may screens in each end of the low pressure fuel pump produce vapor that would cause pump(s) noise. body. This requires removal of the upper elbow and Pump(s) noise that is continuous, and/or cannot the lower fuel filter adapter. If screenscannot be attributed to any of these conditions, could be an sufficiently cleaned, replace the fueU pump. The indicator of fuel system problems screens are not serviced separately. Checking Boat Fuel System The most common causes of failures in the boat fuel system are due to line restrictions or air entry. Typical restrictions are: ¯ kinked, bent, or internally swollen fuel lines ° fuel lines and/or tank selector valve I.D.’s too small -restricted or wrong anti-siphon valve cracked or blocked fuen pick-up or screen inside tank ¯ blocked tank vent Air entry can occur at any point on the suction side of the fuel system. Air in the fuel system is usually indicated by a humming or squealing noise from the pumps. Fuel pump noise can be caused by air being drawn through the fuel pump gears, but is not always an indicator that something is wrong~Momentarynoise has several causes that are not linked to fuel system failures: ° pump(s)may squeal for a short time upon start-up as air is expelled ¯ if ambient temperatures are high, the engine compartment will be subjected to hot operating conditions that may create vapor in the fuel lines . a hot engine after shutdown will go into a "hot soak" condition that may produce fuel vapors ° the use of ethanol fuel will also aggravate this condition as it is more susceptibleto vapor formation VacuumTesting Fuel System CAUTION:This test must be performed with engine under load; either running in gear on water, or in gear and connected to a dynamometer. Ensure that all fuel line connections are leak free. 1. Install VacuumGauge,P/N 390954 (or equiva lent), and 8 in. (20,3 cm) of clear, fuel resistant vinyl hose into the fuel line at the filter bracket inlet. 2. Start engine and allow it to reach normal operating temperature. Run engine at fuji throttle for at least 2 minutes; observe vacuum gauge reading and check clear hose for air or vapor bubbles. Gauge reading must not exceed 4 in. of mercury (Hg) at any time, and there should be no bubbles visible in the clear hose. Compare observationsto the following: Gaugereads1-4 in. of mercury -air bubbles present Supply side of fuel system has an air leak. Check points of possible failure as noted under Checking Boat Fuel System. Repair or replace suspect part, then make another vacuum test to verify repair. Gauge reading exceeds 4 in. of mercury Supply side of fuel system has a restriction. Check points of possible failure as noted under Checking Boat Fuel System. Repair or replace suspect part, then make another vacuum test to verify repair. 4-30 Fuel Sys/eng / DR2065 DR2066 DR2t49 Relay Ohmmeter Tests Throughout this 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 / / ~ot--~ To avoid damaging components or troubleshooting equipment, disconnect the battery cables from the battery and remove the relays before proceeding. DR2149 1. Use a continuity light scale to test continuity. or ohmmeter calibrated on appropriate ~--] 2. Connect meter leads to relay terminals 87a and 30. ® The meter must show continuity. E~] 3. Connect meter leads to e The meter must show relay terminals 87 and 30. no continuity. DR2149 E~_--] 4. Calibrate an ohmmeter the leads to relay terminals 85 e The meter must show on appropriate scale and connect and 86. 70 - 100 ohms. ;~-3~ W/ I~ ~-_] 5. Connect meter leads to relay terminals 87 and 30. Connect a 12 volt source to relay terminals 85 and 86. e The meter must show continuity. ~_-] 6. Connect meter leads to relay terminals 87a and 30. Connect a 12 volt source to relay terminals 85 and 86. V____----J DR2149 e The meter must show no continuity. 7. Replace relay if your test results vary. DR2149 FuelSys,’eng 4-31 Engine Fuel System Troubleshooting ENGMNE DOES NOT START - IMPROPER STARTING PROCEDURE USED 1. Check the following: fueD nevel in tank, fuen tank vent, fuel lines for bbockage, tank to pump fuel line for air leaks, fuel filters for blockage, and anti-siphon valve. 2. Check fuel pump for correct pressure~vacuum. 3. Check vapor separator. ENGINE WiLL START WHEN PRIMED - WiLL NOT CONTINUE TO RUN 1. Check fuel supply. 2. Check fuel lines for blockage, air leaks, anti-siphon valve. 3. Check for plugged fuel filters. 4. Check fueB pump for correct pressure/vacuum. 5. Removevapor separator cover; check for dirt, water, varnish deposits; check float level, and float inret valve operation. ENGINE HARD STARTING, COLD 1. Check fuel pump for correct pressure/vacuum. 2. Check for blockage in fuel lines, air leaks in fuel line from tank to fuel pump. 3. Removevapor separator cover; check float level, inlet valve operation; check for dirt, water, varnish, deposits; check for worn parts, leaking gaskets. ENGINE HARD STARTmNG, HOT 1. Removevapor separator cover; check float Uevel, float inlet valve operation and condition. 2. Check for fuen line on or near hot surfaces, causing percolating in lines. 3. Check fuel tank vent. ENGINE RUNS ROUGH, LOW SPEED 1. Check for dirt or water in fuel, excessive or insufficient fuel pump pressure. 2. Removevapor separator cover; check for proper float level, internan bKockage, defective parts, and varnish deposits in passages. 3. Check other systems; intake manifold for vacuum leaks, sticking valves, overheating, etc. 4. Check setting and operation of throttle plate opening. (continued on next page) FuelSys/eng 4-32 Engine Fuel System Troubleshooting (cont.) ENGINE RUNS ROUGH, HiGH SPEED 1. Check for sufficient fuel in tank, blocked tank vent, anti-siphon valve, proper fuel. 2. Check for water or dirt in fuel; check for correct fuel pump pressure/vacuum; check for blockage or air Ueaks in fuel line. :3.Remove vapor separator cover; check float blockage, varnish, and worn parts. 4. Check for plugged fuel filters. level, float inh.~t valve operation, internal ENGINE DiES (ON iNiTIAL ACCELERATION)OR HAS ACCELEF|ATION FLAT SPOT 1. Check fuel lines for fuel Leaks or partially plugged tank vent. 2. Check for water or dirt in fuel; check fuel pump for correct pressure/vacuum= 3. Remove vapor separator cover; check for dirt and water; check float level and float for operation; check for varnish in passages, worn parts. inlet valve ENGINE WILL NOT TURN RECOMMENDED RPM 5., 6. ;~. 8. 9. 10. tl. 12. 1. Check throttle Jinkage adjustments to be sure throttle opens fully. 2. Check fuel lines for leaks; check fuel pump for correct pressure/vacuum. 3. Remove vapor separator cover; check for dirt and water; check float level and float for operation; check for varnish in passages, worn parts. Check boat for proper trim and propeller; check hull for marine growth. Check Check Check Check Check Check Check Check ignition system components. engine and drive unit for partial seizure. fuel tank for plugged vent; check pickup tube for wacuumleaks. for pEugged fuel filters. for full opening of throttle. exhaust system for restrictions. lower gearcase and propeller for exhaust restrictions. for restricted air intake. inlet valve Torque Specifications Circuit Breaker ................. 20-25 in. Ibs. (2,3-2,8 N-m) Fuel Pressure Regulator Outlet Line ...... 13 ft. Ibs. (17,5 N.m) Circuit Breaker ................. 20-25 in. Ibs. (2,3-2,8 N-m) Engine Control Module ........... 88-124 in. Ibs. (10-14 N-m) Fuel Pressure Regulator ............... 84 in. Ibs. (9,5 N-m) Fuel Rail ............................ 88 in. Ibs. (10 N.m) Idle Air Control Valve Coolant Cover ...... 28 in. Ibs. (3,2 N-m) Idle Air Control Valve ................. 28 in. Ibs. (3,2 N.m) Intake Plenum ........................ 15 ft. Ibs. (20 N.m) Manifold Absolute Pressure Sensor .... 44-62 in. Ibs. (5-7 N.m) Throttle Body Assembly ................ 11 ft. Ibs. (15 N.m) Throttle Position Sensor ................ 18 in. Ibs. (2 N.m) Engine Coolant Temperature Sender ..... 108 in. Ibs. (12 N.m) Intake Air Temperature Sensor ........... 11 ft. Ibs. (15 N-m) Knock Sensor ................... 11-16 ft. Ibs. (15-22 N.m) 4-34 FuelSysleng Section 5 GM TBi Fuel System Table of Contents Electrical System Circuit Breaker ................................... 5-25 Engine Control Module ............................. 5-3 Engine Coolant Temperature Sensor ................ 5-4 Fuel Pump (Low Pressure) ......................... 5-17 Fuel Pump (High Pressure) ........................ 5-23 Idle Air Control Valve ............................. 5-6 Knock Sensor .................................... 5-8 Knock Sensor Module ............................. 5-8 Manifoid Absolute Pressure Sensor .................. 5-4 Relay .......................................... 5-25 Relay Ohmmeter Tests ........................... 5-26 Throttle Position Sensor ............................ 5-5 Flame Arrestor ...................................... 5-10 Fuel System Filter Bracket .................................... 5-27 Fuel Control Service ............................... 5-9 Fuel injectors ................................... 5-14 Fuel Reservoir .................................. 5-20 Fuel Meter Body Assembly ......................... 5-15 Fuel Meter Cover Assembly ........................ 5-13 Fuel Pressure Relief Procedure ...................... 5-9 Throttle Body injector Unit ........................ 5-11 General Information .................................... 5-3 Torque Specifications .................................. 5-32 Troubleshooting Checking Boat Fuel System ....................... 5-29 Checking Engine Fuel System ..................... 5-28 Electric Pump(s) ................................. 5-28 Engine Fuel System .............................. 5-30 Vacuum Testing Fuel System ....................... 5-29 5-1 Z~ Read and comply with all notes and safety warnings while performing service procedures to avoid personal injury or damage to components, if a fastener needs to be replaced, use the correct part number fastener for that application. A fastener of equal size and strength (or stronger) may be used if the correct part number is not available. Z~ Safety Warnings Before working on any part of the fuel system, read the section called Safety at the end of this manual. The original mounting, support, and routing of the fuel system parts conform with U. S. Coast Guard requirements, it is important to maintain the original mounting, support, and routing after servicing the fuel system= Gasoline is extremely flammable and highly explosive under certain conditions. Ensure good venti|ation. Do not smoke or allow open flames or sparks near fuel system or in engine compartment while servicing. When making instrument attachments or working around an engine being run or cranked, use extreme care to avoid getting hands, fingers, or clothing caught in the alternator and water pump belts, pulleys, and other moving parts. 5-2 FuelSys/eng General Information The ECM and all EF~ sensors are sensitive electronic components. Observe the following cautions when servicing them" e Verify the ignition switch is in the "OFF" position, and remove both battery cables from the battery, ¯ DO NOT soak components in any liquid cleaner or solvent; this will damage them. e Handle components carefully; any damage will affect proper operation of the EFI system. ¯ Make sure new components have the same part number as old ones; this will ensure proper engine performance. Engine Control Module (ECM) Removal When replacing the ECM, the ignition must be "OFF". Remove both battery cables before disconnecting or reconnecting the ECM "Jl" and "J2" connectors to prevent internal damage to the ECM. To prevent possible electrostatic discharge damage to the ECM, DO NOT touch the connector pins. The ECM is an electrical component that can easily be damaged by static electricity, iDo not soak the ECM in any liquid cleaner or solvent, as damage may result. 1. Removeflame arrestor cover and set it aside. [~] 2. Remove the "Jl" ~) and "J2" ® connectors from the EC:M ©, L~ 3. Unscrew four ECM mounting screws @. Remove the ECM from the mounting bracket. Installation ~] 1. Attach the new ECM to the mounting bracket and secure with four screws. Tighten the screws (~ to 88-124 in. Ibs. (10-.14 N.m). [’4~ 2. Attach "J1" ~ and "J2" ® connectors to ECM. Check for a secure attachment. 3. Install the flame arrestor cover. Tighten the nut to 25-35 in. Ibs. (2,8-4,0 N.m). 37674 37676 37677 37673 FLtelSys/eng ~ Safety Related Engine Coolant Temperature (ECT) Sensor Removal [~ 1. Remove the ECT sensor electrical connector E~ 2. Unscrew the ECT sensor from the thermostat housing. installation 1. Coat the ECT sensor threads with pipe sealant with Teflon. [~ 2. Install the ECT sensor ~) into the thermostat housing. Tighten the sensor to 108 in. lb. (12 N-m). [~ 3. Attach the ECT sensor electrical connector ®. Check for a secure attachment. Manifold Absolute Pressure (MAP) Sensor Removal 1= Remove the flame arrestor cover from the engine. 2. Removethe MAP sensor electrical connector @. Remove the "J2" connector @ from the ECM. 37678 37679 37680 37681 5-4 FuelSys, eng 37653 37654 [~ 3. Unscrew two screws (~ securing MAP sensor O to bracket. Remove MAP sensor. [~7~ 4. Loosen clamp @ and remove vacuum hose ® from sensor. installation L~ 1. Attach vacuum hose®to MAP sensor. Secure with clamp @. 37656 [~9__~ 2. Place MAP sensor ® on bracket and secure with two screws (~. Tighten screws to 44-62 in. Ibs. (5-7 N.m). [~] 3. Attach MAP sensor electrical connector ©. Attach the "J2" electrical connector @ to the ECM. Check for a secure attachment. 4. Install the flame arrestor cover. Tighten the nut to 25-35 in. Ibs. (2,8-4,0 N.m). Throttle Position (TP) Sensor 37657 Removal 1. Remove flame arrestor cover from the engine. rlEl~ 2. Remove TP sensor electrical connector O. 37658 FuelSys;eng 5-5 37660 37661 E~ [~ 3. Unscrew two screws @ securing TP sensor to throttle body. Remove TP sensor ® and seal @. Installation If replacing the TP sensor, use the new screws that are supplied with the TP sensor service package. [~ 1. Place the seab © on the TP sensor. [~ 2. Verify that the throttle plates are closed. Position the TP 37866 sensor on the throttle shaft and align the screw holes. Install two mounting screws (~) and tighten to 18 in. tbs. (2 N.m). 3. Attach the TP sensor electrical connector @. 4. install the flame arrestor cover. Tighten the nut to 25-35 in. Ibs. (2,8-4,0 N.m). Idle Air Control (IAC) Valve Removal 37713 1. Remove flame arrestor cover from the engine. E~ 2. Remove IAC valve electrical connector ~. 37714 -6 -6 FuelSys eng ~ 3. Unscrew two screws ® securing IAC valve to throttle body. Remove IAC valve and discard O-ring @. ff an IAC valve I~as been in service, DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent. This will damage the va lye. Cleaning and inspection Both original and replacement IAC valves have a special factory locking compound applied to the screw threads. If the valve removed from the throttle body is being reinstalled, do not remove the thread locking compound that may be on the threads. Clean the IAC valve O-ring sealing surface, pintle valve seat, and air passage. Use carburetor cleaner to remove carbon deposits. DO NOT use 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 misalignmen[ or a bent pintle shaft. Insta01ation Nr’N~t_e-~ If installing a new IAC valve, be sure to replace it with an identical part. The b~,C valve pintle shape and diameter are designed for specific applications. 1. If installing a new IAC valve, measure the distance between the tip ® of the IAC valve pintle and the mounting surface O. If the measurement is greater than 1.102 in. (28 ram), use finger pressure to slowKy retract the pintle. The force required to retract the pintle ot a new valve will not cause damage to the va I ve. ~’t [~ 2. Lightly lubricate a new O-ring @ with engine oil and place it on the IAC valve. Install the valve into the throttle body and secure with two ,,;crews O. Tighten the screws to 28 in. Ibs. (3,2 N.m}. 1~[ 3. Attach the IAC valve electrical connector (~). Check for secure attachment. 37715 DR5524 ~-~. ~ 37716 37717 4. Install the flame arrestor cover and tighten the nut to 25-35 in. lb. (2,8-4,0 N-m). 5. Reset the IAC valve pintle position as follows: Start and run engine for 30 seconds Turn ignition "OFF" for 10 seconds Restart engine and check for proper idle operation. Knock Sensor (KS) Removal 37719 [~ 1. Remove the knock sensor electrical connector ®. [~ 2. Unscrew the knock sensor ® from the engine block. Use a wrenchto keep the T-fitting from rotating. Installation Install the knock sensor module in the same location as the old one. Makesure the threads are clean. If installing the knock sensor in a water jacket, coat the threads with pipe sealant with Teflon. 37720 [~ 1. Thread the knock sensor ® into the engine block and tighten to 11-16 ft. lb. (15-22 N-m). Use a wrench to keep the T-fitting from rotating. [~ 2. Attach the knock sensor electrical connector @. Knock Sensor (KS) Module 1. Removethe flame arrestor cover from the engine. [~ 2. Remove the knock sensor module electrical connector @. 37721 5-8 FuelSys, eng ~] 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 @. Tighten the screws securely. 2. Attach the module electrical connector @. 3. Install the flame arrestor cover and tighten the nut to 25-35 in. Ibs. (2,8-4,0 N.m). 37694 Fuel Control Service Z~ The following is general information concerning working on the fuel system: ¯ Always keep a dry chemical fire extinguisher near the work area. ¯ Fuel line fittings require new O-rings when assembling. 37695 To reduce the risk of fire and personal injury, relieve the fuel system pressure before servicing any fuel system components. Always allow fuel pressure to bleed off before disassembling parts. Do not make any repairs on the fuel system until you have read the instructions and checked the figures relating to the repairs= ¯ DO NOT replace fuel lines with fuel hose. ¯ Observe all safety warnings and informational notes. m 8 37696 Fuel Pressure Relief Procedure Z~ 1. Disconnect the negative battery cable from the battery to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. The internal constant bleed feature of the TBI unit relieves fuel pump system pressure when the engine is turned "OFF". Therefore, no further pressure relief procedure is required. F,,~sy,~g ~ Safety Related 5-9 After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. To reduce the chance of personal injury, cover the fuel line fittings with a shop towel before disconnecting to catch any fuel that may leak out. Place the towel in an approved container when service is completed. Flame Arrestor Removal [~ 1. Remove flame arrestor cover retaining nut (~. Remove the cover ® from the engine. [~ 2. Remove the flame arrestor nut ©, two breather hose brackets @, and the arrestor ~ from the throttle body. 3. Remove injector baffle ® from flame arrestor stud. inspection Z~ Inspect the flame arrestor element for dust, dirt, water, or damage. Clean or replace as necessary. installation 1. Place the injector baffle ® on the flame arrestor stud. [~E] 2. Place the flame arrestor (~ on the throttle body. Attach two breather hose brackets @ to the flame arrestor stud. EEl ~ 3. Secure the flame arrestor with retaining nut ©. Tighten nut to 25-35 in. Ibs. (2,8-4,0 N.m). EEl 4. Place flame arrestor cover (~ on the engine and secure with nut ~. Tighten nut to 25-35 in. Ibs. (2,8-4,0 N.m). 37867 37697 37868 © \ Safety Related 5-10 FuelSys]eng Throttle Body injector (TBI) Unit Removal 1. Remove flame arrestor following instructions found elsewhere in this section. [~] 2. Remove the electrical connectors from the IAC valve @ and TP sensor ®. [~ 3. Remove the electrical connectors (~ from the injectors by squeezing the tabs on the injectors and pulling straight up. Remove grommet @ with wires from throttle body. 4. Remove cotter pin and washer securing throttle cable to throttle body lever. Removethrottle cable from throttle body. 5. Remove the distributor cap and ignition wires to allow access to the back of the throttle body. Disconnect the MAP sensor vacuum hose ®. [~ Z~ 6. Refer to Fuel Pressure Relief Procedures before disconnecting fuel lines. Removehigh pressure (~ and return ~) fuel lines using a flare nut wrench to prevent damage to lines or fittings. Hold the throttle body line fittings to prevent them from turning. Removefuel line O-rings and discard. [-~ 7. Remove TBI mounting nuts (~ and TBI from adaptor plate. Remove and discard throttle body mounting gasket. Stuff a rag in the intake manifold opening to prevent foreign material from entering the engine. Use care when removing old gasket material from the intake manifold. Failure to do so may result in damage to the manifold. To prevent damage to the throttle valve, it is essential that the unit be placed on a holding fixture before performing service. Cleaning and inspection -[hrott~e bore and valve deposits may be cJeaned using carburetor cleaner and a parts cleaning brush. Do not use a cleaner that contains methyl ethyl ketone, an extremely strong solvent, and not necessary for this type of deposit. The throttle body metal parts may be cleaned following disassembly in a cold, immersion type cleaner. 37706 37711 37710 37705 The fuel injectors, pressure regulator, TP sensor, TP sensor gasket, and IAC valve should not come in contact with solvent or cleaner, as they may be damaged. These parts should be removed prior to immersion. Clean all metal parts thoroughly and blow dry with compressed air. Be sure that all fuel and air passages are free of dirt and burrs. Inspect mating surfaces for damage that could affect gasket sealing, and inspect the throttle body for cracks in the casting. A small vial of thread locking compound is supplied in the service repair kit with directions for use. If the material is not available, use Loctite 262 or equivalent. Do not use a higher strength locking compound than recommended. To do so could make removing the screw extremely difficult, or result in damaging the screw head. Inspect the manifold bore for loose parts and foreign material. Check the intake manifold mating surface for cleanliness and burrs that can affect gasket sealing. Installation [~ 1. Install a new TBI flange (manifold mounting) gasket. Install the TBI and secure with mounting nuts @. Tighten the nuts to 12 ft. Ibs. (16 N-m). [~ 2. Connect the vacuum hose ® to the throttle body nipple. Secure with tie strap ©. Install new O-rings on the fuel lines. Connect the high pressure @ and return (~) fuel lines to the throttle body. Hold the throttle body line fittings to prevent them from turning, and tighten the line nuts to 17 ft. Ibs. (23 N.m). Z~ 3. Attach the throttle cable to the throttle body. Secure with flat washer and cotter pin. Bend the ends of the cotter pin for a secure attachment. Check for proper adjustment. E~] 4. Attach the grommet (~ with wiring harness to the throttle body. Connect all electrical connectors to the IAC valve @, TP sensor ®, and fuel injectors (~. 37712 37784 37703 37687 //~ Safety Related 5-12 FuelSys;eng 5. Check to see if the [hrottle is free, by moving the throttle lever to full open and back to full close while the engine is "OFF". /~ 6. Check for fuel leaks with the key switch "ON" and the engine "OFF". 7. install the flame arrestor following the instructions found elsewhere in this section. :3. Start the engine and check for fuel leaks. Fuel Meter Cover Assembly Removal The fuel meter cover assembly contains the fuel pressure regulator assembly. The regulator has been adjusted at the factory and should only be serviced as a complete preset assembly. Z~ DO NOT remove the four screws securing the pressure regulator to the fuel meter cover. The fuel pressure regulator includes a large spring under heavy compression which, if accidentally released, could cause personal injury. Disassembly might also result in a fuel leak between the diaphragm and the regulator container. 1. Remove the flame arrestor following instructions found elsewhere in this section. I~ 2. Remove electrical connectors (~ from injectors by squeezing plastic tabs on injectors and pulling straight up. ° ~ 3. Unscrew the flame arrestor stud ® 180 to allow access to retaining screws. Remove long (~ and short (~ fuel meter cover screws. Remove the fuel meter cover assembly. Remove and discard gaskets ~ and @. DO NOT immerse the fuel meter cover (with pressure reguJator) in cleaner, as damage to the regulator diaphragm and gasket could occur. inspection inspect all components for dirt, foreign material, and casting warpage. 37888 37689 37690 37690 37689 installation [~ ~ [~ 1. Install a new fuel meter outlet gasket @ and cover gasket ® on the fuel meter cover. InstaUl the cover assembly on the throttle body. Install the short retaining screws © next to the injectors. Install the long retaining screws @. Tighten the screws to 28 in. Ibs. (3,0 N.m). Tighten the flame arrestor stud ° 180 after tightening the screws. [~ 2. Attach the electrical connectors ® to the fuel injectors. Z~ 3. Turn "ON" the ignition switch but DO NOT start the engine. Check for fuel leaks around the gasket and fuel line couplings. 4. Install the flame arrestor following instructions found elsewhere in this section. Fuel injectors Removal Use care in removing the fuel injectors to prevent damage to the electrical connector terminals, the injector fiBter, and the fuel nozzle. The fuel injector is serviced as a complete assembly only. Also, since the injectors are electrical components, they should not be immersed in any type of liquid solvent or cleaner as ® damage may occur. 1. Remove the fuel meter cover assembly following the proce-© dures found elsewhere in this section. E~] 2. Push with your finger on the injector tip and remove the injector from the throttle body. [~ 3. Remove lower (small) O-rings @ from the nozzle of the injectors. Removethe upper (large) O-rings ® from the top of the fuel injector. Discard the O-rings. 37692 37723 ® Q 37724 Z~ Safety Related 5-14 FuelSys/eng inspection Inspect fuel filter for evidence If present, of dirt and contamination. checkfor presence of dirt in fuel lines and fuel tank. installation [Z]"~;~~";,u~~~t Be sure to replace the injector with one having an identical part number. Injectors from other models can also fit into the TBI, but are calibrated for different flow rates. DR5526 E~] 1. Lubricate new lower (small) O-rings with DuraPIusTM Power Trim/Tilt and Steering Fluid, and push on nozzle end of the injector until it presses against the fuel injector filter. 2. Lubricate a new upper (large) O-ring with DuraPIus TM Power Trim/ Tilt and Steering Fluid, and install it in the injector opening. Be sure \ O-ring is seated properly and is flush with top of fuel meter body surface. Large O-rings must be installed before injectors, or improper seating of the large O-ring could cause fuel to leak. 37725 3. Install the injectors. Align the raised lug on each injector base with the notch in the fuel meter body cavity. Push down on the injector until it is fully seated in the fuel meter body. The electrical terminals of the injectors should be in line with the throttle shaft. ~i~ Be sure to install the injectors in their proper location, 4. Install the fuel meter cover and gasket following the procedures found elsewhere in this section. 5. Install the electrical connectors on the fuel injectors. 37726 //~k 6. Turn the key switch "ON" but DO NOT start the engine. Check the fuel system for leaks. Fuel Meter Body Assembly Removal 1. Removefuel meter cover assembly and injectors following the procedures found elsewhere in this section. 2. Removedistributor cap to allow access to high pressure and return fuel lines. Remove both lines and discard the O-rings. 37727 [~ 3. Remove the high pressure (~ and return ® nuts and gaskets. Discard the gaskets. V]M.PO~~ Note the location of the nuts for proper reassembly later. The inlet (high pressure) nut has a larger passage than the outlet nut. [~] 4. Remove the flame arrestor stud © and fuel meter body mounting screws ©. Remove the fuel meter body assembly ® from the throttle body. Discard the gasket between the assemblies. irttstallatiort 1. Place a new throttle body to fuel meter body gasket on the throttle body. Match the cut-out portions in the gasket with openings in the throttle body. [-~ ~] 2. Place the fuel meter body assembly (~ on the throttle body. Apply Loctitie 242 TM to the threads of the mounting screws. Install the mounting screws @ and tighten the screws to 30 in. lb. (4,0 N-m). Instali the flame arrestor stud ©. Align the bend in the stud over the center of the throttle body. 3. Install the high pressure (~ and return (~ fuel nuts with new gaskets in the fuel meter body assembly. Tighten the high pressure nut to 30 ft. lb. (40 N-m). Tighten the return nut to 21 ft. lb. (29 N-m). [~ 4. Install the high pressure @ and return ® fuel lines using new O-rings. Tighten the fittings to 17 ft. lb. (23 N-m). Use a wrench keep the TBI nuts from turning. 5. Install the fuel injectors and fuel meter cover following procedures found elsewhere in this section. ~6. Turn "ON" the ignition switch but DO NOT start the engine. Check for fuel leaks around fuel meter body, gasket, and fuel line nuts. 37728 37729 37730 Z~ Safety Reaated 5-16 Fuo~Sys/eng Fuel Pump -Low Pressure Removal Z~ This pump has been designed to meet U.S. Coast Guard fuel systems regulations for marine use. Do not substitute other brands or models that may be similar in appearance. Use of a substitute pump could result in leakage of fuel or fumes, and cause fire and explosion. Z~ 1. Verify the ignition switch is in the "OFF" position. Discon.. nect negative cable from the battery. 30641 Z~ 2. Disconnect boat fuel supply line at fuel filter and install plug O. E~ E~ 3. cut tie strap @ holding electrical leads to pump. Pull connector ® off pump suppressor. r=-R-1 lel 4. Using two wrenches, one holding pump elbow and other on fuel line nut, unscrew fuel line (D at pump and pull line out of elbow. 5. Hold the pump end cap with an open end wrench ~), and 30639 loosen the holddown lock nut ~ below the elbow. Unscrew the elbow. Z~ ff pump end cap is not held when removing nut, end cap may rotate and damage internal O-ring that seals pump against external fue~ leakage. 1~1 6. Remove two bolts @ and filter bracket. Slide pump out of grommet (E) in upper bracket after last bolt is removed. Z~ Fuel filter may contain fuel; be careful not to spill it. 30630 Fue[Sys,’P, ng ~ Safety Related 7. To remove fuel filter and bracket from pump, hold pump end cap (~ with an open end wrench, and unscrew adapter at base of pump. Z~ If pump end cap is may rotate and external fuel leakage. damagnot e inteheld rnal when removing adapter, O-ring that seals pump against end cap installation [~ 1. Place a new O-ring (~) on the filter bracket adaptor and position it against hex. Do not nick or cut O-ring on threads. This O-ring is made of a special fuel resistant material Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. ~] 2. Screw filter bracket assembly into pump. Hold lower pump end cap (~)with an open end wrench and tighten adaptor 8-10 ft. Ibs. (11-14 N-m). Z~ If pump end cap is not held when instal|ing adapter, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. [-~ 3. Slide pump up through grommet © and install two bolts @. Tighten bolts to 20-25 ft. Ibs. (27-34 N.m). [~ 4. Before installing upper elbow, turn nut ~ up against head of elbow. Slide washer and O-ring (~ up against nut. Do not nick or cut O-ring on threads. This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. 30635 30626 30634 Z~ Safety Related 5-18 FuelSys, eng [~ ~ 5. Screw elbow all the way into pump outlet, then back it off until it aligns with the fuel line. Attach fuel line, and while holding elbow, tighten line fitting securely. [~ ~ 6. Screw elbow lock nut ~ down against pump outlet. Hold pump end cap @ with an open end wrench and tighten nut to 60-84 in. lb. (6,8-9,5 N-m). ~,CAUTIONif pump end cap is not held when tightening nut, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. [~ 7. Align connector tabs @ and push connector onto pump suppresseruntil it clicks into place, if the suppresser holes are open, coat them with liquid neoprene to prevent water entry. [~ 8. install tie strap to hold electrical leads against pump body. Z~9 Connect boat fuel line. Attach negative cable to the battery. Tighten nut securely. Run engine and check for fuel leaks. . -i . ~ " 30621 30639 30641 FuelSys’eng ~ Safety Renated 37764 45182 45183 Fuel Reservoir Removal [~ 1. Loosen hose clamp ~ and remove water outlet hose ® from fuel reservoir. [~ 2. Remove nut © securing power steering cooler to the fuel reservoir. Remove the cooler and position out of the way. Remove and save flat washer behind cooler. 37765 ~] 3. Cut the tie strap, then unplug the electrical connector from the high pressure fuel pump. [~ 4. Loosen clamp (~ and remove reservoir vent hose (~ from reservoir. [~ 5. Remove low pressure inlet line @ and return line ®, 6. Remove fuel pump high pressure line 0. 37766 37767 5-20 Fue[Sys,’eng ~__~[ 7. Loosen clamp and remove thermostat housing cooling hose @. 8. Removescrew and nut ® and screw (D securing reservoir to the engine. Remove the reservoir. Float Level Setting 1. Unscrew the reservoir cover screws and remove the cover’. Discard the cover gasket. ~’_1 2. Turn the reservoir cover over to allow the float to seat the float needle. ~1 3. Measure from the top of the float to the inside surface of the cover. Adjust the float to a 3/16 in. CLu) (4,76 mm) measurement by lightly bending the adjustment tab (~. After setting the float level, ensure free float movementon the float pivot pin. Do not force the viton tipped float needle against the needle seat or the resilient needle tip may be damaged. 4. Place a new cover gasket on top of the reservoir. Install the cover and secure with eight screws. Tighten the screws to 25-3!5 in. Ibs. (2,8-4,0 N-m). Installation I. Install the fuel reservoir and secure with screw and nut ®, and screw @. Tighten the screws to 28-36 ft. Ibs. (38-49 N-m). [~ 2. Attach thermostat housing cooling hose @ to reservoir and secure with clamp @. 37768 45184 T DR4549 45185 37735 37737 ~] ~ 3. Attach high pressure fuel line (~ to pump. Tighten line fittings to 10-12 ft. Ibs. (13,6-16,3 N.m). [~ Z~ 4= Attach fuel return line ® to the fuel reservoir. Tighten line fittings to 10-12 ft. Ibs. (13,6-16,3 N.m}. [~ Z~ 5. Attach low pressure fuel line © to fuel reservoir. Tighten line fitting to 1g=12ft. Ibs. (13,6-16,3 N.m). [~] Z~ 6. Attach intake manifold vent hose @ to reservoir. Secure with clamp (~) to prevent leakage of fuel fumes. 45186 r~ 7. Connect two-wire connector (~) to fuel pump. Secure with tie strap @. [~ 8. Place thick flat washer ® onto reservoir stud. E~ 9. install power steering cooler onto reservoir stud. Secure with thin fiat washer and lock nut ~. Tighten lock nut to 20-25 ft. Ibs. (27-34 N.m). 10. Attach cooling outlet (~ hose to the reservoir. Secure with hose clamp ®. 45187 /~ 11. Energize fuel pumpsand check for leaks. 45188 Z~ Safety Related 5-22 FuelSys,,eng Fuel Pump -High Pressure Removal ~-I off [~ 1. Make note of the position of the elbow ~, then back the elbow lock nut ~. Unscrew the elbow from the pump. 7~ 2. Unscrew the two screws@ securing the end bracket® the reservoir. Remove the bracket from the pump. to ~__I 3. Unscrew the banjo nut from the remove the pump. Discard all O-rings. end of the pump and 37770 installation [~ 1. Lubricate one new small O-ring @ with engine oil and place it on the threaded end of the elbow. Lubricate one large O-ring ® with engine oil. Place it on the banjo nut in the O-ring groove closest to the: hex head. Z~ These O-rings are made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibiility of fire and explosion. l~j 2. Install banjo nut ® into hole in reservoir cover. Lubricate a second new large O-.ring (~) with engine oil. Place the O-ring the threaded end of the banjo nut. 37733 Z~ This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. !" i! 32122 ® .{ @j 4 il ® FuelS/s/eng ~t~ Safety Related 5-23 [~ ~ 3. Thread the banjo nut into the high pressure fuel ° pump. Position the pump at a 45 angle. Hold pump end cap with a wrench, and tighten the banjo nut to 38-22 ft. Ibs. (24,4-29,8 N.m). Z~ if pump end cap is not held when installing banjo nut, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage. ~] 4. Place end bracket (~)over the end of the pump. Secure the bracket to the reservoir cover with two screws ~. Tighten the screws to 25-35 in. Ibs. (2,8-4,0 N.m}. ~] ~ Z~ 5= Attach the elbow to the end of the pump. Position the elbow as noted in the removal procedure. Screw the elbow lock nut © down against the pump outlet. Hold the elbow (~ with an open end wrench and tighten lock nut © to 60-84 in. Ibs. (6,8-9,5 N.m}. Z~ if eabow is not held when tightening lock nut, elbow may rotate and damage internal O-ring that seals pump against external fuel leakage. Z~ Safety Related 5-24 FuelSys/eng Circuit Breaker Volvo Penta’s EFI GM engines have four circuit breakers as protectiondevices: ¯ A 12.5 amp circuit breaker protects the fuel injector relay and ECM ° A 50 amp circuit breaker protects the trim/tilt motor A 60 amp circuit breaker protects the main engine harness A 20 amp circuit breaker protects the fuel pump relay and circuit Models have a 10 amp circuit breaker, located on the trim/tilt pumpto protect the pump relay. If this component the ECM or circuit fails, will not store a service code in the memory. Circuit Breaker RepRacement ~WAR~NG To prevent sparks, damaged components, or possible personal injury, disconnect the battery before servicing any circuit breaker, 1. Makea note of the lead position, then remove all the leads from circuit breaker. Remove circuit the screws and nuts, and lift breaker out of bracket. 2. install new circuit breaker and secure with screws and nuts. Tighten screws to 20-25 in. lb. (2,3-2,8 N-m). 3. Attach the leads to their original positions on the circuit breaker and secure with the nuts. Tighten the nuts to 20-25 in. lb. (2,3-2,8 N- m). Coat the terminals with liquid neoprene. Relay ~] Replace the relay ® by pulling it off its mounting bracket. Install the relay by aligning the terminals of the relay with the bracket. Push the relay in until it seats. DR4640 g Z~ Safety Related Fuo~sv 5-25 .... Relay Ohmmeter Tests [~ Throughout this 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 (oo). To avoid damaging components or troubleshooting equipment, disconnect the battery cables from the battery and remove the relays before proceeding. 1. Use a continuity light or ohmmeter calibrated on appropriate scale to test continuity. ~] 2. Connect meter leads to relay terminals 87a and 30. ¯ The meter must show continuity. 3. Connect meter leads to relay terminals 87 and 30. ¯ The meter must show no continuity. E~ 4. Calibrate an ohmmeter on appropriate scale and connect the leads to relay terminals 85 and 86. ® The meter must show 70 -t00 ohms. [~ 5. Connect meter leads to relay terminals 87 and 30. Connect a 12 volt source to relay terminals 85 and 86. / ¯ The meter must show continuity. E~ 6. Connect meter leads to relay terminals 87a and 30. Connect a 12 volt source to relay terminals 85 and 86. ¯ The meter must show no continuity. 7. Replace relay if your test results vary. l I DR2065 DR2066 / DR2149 / DR214g 70-100G) ) DR2149 5-26 FueiSys/eng Fiffer Bracket ~_-ot~ The electric fuel pump filter has an internal seal around the fueR exit point that prevents leakage and drain back. Do not substitute other filters that may be similar in appearance. To replace filter canister, refer to Fuel Filter Replacement in this section. elsewhere 1. Removefuel pump and filter bracket assembly from mounting bracket. 2. Unscrewfuel inlet elbow and save for installation on new bracket. 3. Clamp filter bracket in a vise and unscrew adapter and pump assembly. Discard bracket. 4. Thoroughly clean adapter threads to remove old sealer, then apply DR2149 pipe sealant with Teflon to the threads. 5. Clamp new bracket in a vise. Screw in adapter and pump assembly.. and tighten to at least 10 ft. lb. (14 N-m). Continue tightening~ adapter to achieve proper pump/bracket directional alignment. Do not exceed 32 ft. lb. (43 N-m) torque. 6. Thoroughlyclean threads of inlet elbow to remove old sealer, then apply pipe sealant with Teflon to the threads. Screw in elbow and tighten to at least 12 ft. lb. (16 N-m). Continue tightening elbow achieve proper directional alignment. Do not exceed 32 ft. lb. (43 N-m)torque. DR2149 7. Install fuel pump and filter bracket assembly in mounting bracket. ~..~ 8. Run engine and check for fuel leaks. FuetSys/eng ~ Safety Related 5-27 TroubleshootingElectric Pump(s) Start by verifying the pumps are receiving a mini mumof 12.0 + 1 volt. Removethe connector from each pump suppresser. Disable ignition to prevent engine from running, then crank engine and check yellow/green lead with a voltmeter. Turn key off, then check connector black lead with an ohmmeter for a good ground. If voltage is not as specified, or ground path is suspect, check: ¯ relay and bracket circuit breaker wiring related to all of the above Ensure all items are functioning correctly before proceeding. As voltage to the pump drops, so will its output capability. 2. Once it has been established that the pumps are receiving proper voltage, separate the engine fuel system from the boat’s fuel system. Disconnect the supply line at the pump’s fuel filter, and place a pick-up hose in a vented fuel container. The pick-up hose must have a minimum I.D. of 3/8 in. I~RNIING Do not connect engine fuel system to any supply system having a pressure producing device such as an outboard fuel tank with primer bulb, or another etectric fuel pump located elsewhere in the boat or at the fuel tank. The pumps are sensitive to additional fuel pressure, and will add this to its own output. The result will be a continually flooding fuel reservoir with the possibility of external fuel leaks, and the potential for fire and explosion. 3. Run engine to see if problemstill exists. If problem has been eliminated, source is located somewhere in boat fuel system back to, and including, the boat fuel tank. If problem still occurs, it is located somewhere in engine fuel system. Checking Engine Fuel System 1. The electric fuel pumps require an unrestricted, airtight fuel supply. Unscrew the tow pressure fuel pumpfilter and check it for debris. Also check that the filter seals tightly against its fixture and the center mounting threads. Make sure the fi~ter is the correct one for this application. Check threads of filter inUet elbow to ensure a tight seal. If any of these conditions are in doubt, correct them before continuing. ,&CAUTION2o Check both fuel pump mounting positions. Pumps must always be located on engine in original factory position. This posi= tion is determined by US Coast Guard regulations and must be complied with. Never relocate pumpto transom, stringer, fuel tank, or any point other than its original location on the engine. Pressure Testing Fuel System [~ Pressure test fuel system using appropriate equipment. The foffowing pieces are available from OwatonnaTool Co. They feature leak-free connections and the ability to depressurize and drain the fuel lines. ¯ EFI Fuel Pressure Gauge OTC-7211 , Adapter OTC-7272 Z~ Pump(s) performance can be verified checking pump(s) PSI at specific engine RPM. This test must be performed with engine under load; either running in gear on water, or in gear and connectedto a dynamometer. Use a good quality fuel pressure gauge. Follow the gauge manufacturer’sinstructions for installation, and ensure that connections are leak free. Refer to GM EFI Diagnostic Manual, Fuel System section to check pump’s operating pressure. New pumps will generally have lower operating pressures. As the gears break in, contact improves and the pump’s pressure will increase slightly. Two other items that would require checking are the screens in eachend of the low pressure fuel pump body. This requires removal of the upper elbow and the lower fuel filter adapter. If screens cannot be sufficiently cleaned, replace the fuel pump. The screens are not serviced separately. Z~ Safety Related 5-28 FuelSys/eng Checking Boat Fuel System The most common in the boat causes of failures fuel system are due to line restrictions or air entry. Typical restrictions are: kinked, bent, or internally swollen fuel lines ¯ fuel lines and/or tank selector valve I.D.’s too small restricted or wrong anti-siphon valve ° crackedorr blocked fuel pick-up or screen inside tank ¯ blocked tank vent Air entry can occur at any point on the suction side of the fuel system. Air in the fuel system is usually indicated by a humming or squealing noise from the pumps. Fuel pump noise can be caused by air being drawn through the fuel pump gears, but is not always an indicator that something is wrong. Momentary noise has several causes that are not linked to fuel system failures: ¯ pump(s)may squeal for a short time upon start-up as air is expelled ° if ambient temperatures are high, the engine compartment be subjected to will hot operating conditions that may create vapor in the fuel lines ¯ a hot engine after shutdown will go into a "hot soak" condition that may produce fuel vapors ° the use of ethanol fuel will also aggravate this condition as it is more susceptibleto vapor formation All of these situations are temporary, but may produce vapor that would cause pump(s) noise. Pump(s) noise that is continuous, and/or cannot attributed to any of these conditions, could be an indicator of fuel system problems VacuumTesting Fuel System ~CAUTION must be performed with This test engine under load; either running in gear on water, or in gear and connected to a dynamometer. Ensure that all fuel line connectionsare leak free. 1. Install VacuumGauge,and 8 in. (20,3 cm) clear, fuel resistant vinyl hose into the fuel line at the filter bracket inlet. 2. Start engine and allow it to reach normal operating temperature. Run engine at full throttle for at least 2 minutes; observe vacuum gauge reading and check clear hose for air or vapor bubbles. Gauge reading must not exceed 4 in. of mercury (Hg) at any time, and there should be no bubbles visible in the clear hose. Compare observations to the following: Gaugereads 1-4 in. of mercury -air bubbles present Supply side of fuel system has an air leak. Check points of possible failure as noted under Checking Boat Fuel System. Repair or replace suspect part, then make another vacuum test to verify repair. Gauge reading exceeds 4 in. of mercury Supply side of fuel system has a restriction. Check points of possible failure as noted under Checking Boat Fuel System. Repair or replace suspect part, then make another vacuum test to verify repair. FuelSys/eng ,~ Safety’ Related 5-29 Engine Fuel System Troubleshooting 1. Check the following: fuel level in tank, fuel tank vent, fuel lines for blockage, tank to pump fuel line for air leaks, fuel filters for blockage, and anti-siphon valve. 2. Check fuel pump for correct pressure/vacuum. 3. Check vapor separator. 1. Check fuel supply. 2. Check fuel lines for blockage, air leaks, anti-siphon valve. 3. Check for plugged fuel filters. 4. Check fuel pump for correct pressure/vacuum. 5. Removevapor separator cover; check for dirt, water, varnish deposits; check float level, and float inlet valve operation. 1. Check fuel pump for correct pressure/vacuum. 2. Check for blockage in fuel lines, air leaks in fuel line from tank to fuet pump. 3. Removevapor separator cover; check float level, inlet valve operation; check for dirt, water, varnish, deposits; check for worn parts, leaking gaskets. , A’I ~ e__ 1. Removevapor separator cover; check float level, float inlet valve operation and condition. 2. Check for fuel line on or near hot surfaces, causing percolating in lines. 3. Check fuet tank vent. " "O I ® I I.Check for dirt or water in fuel, excessive fuel pump pressure. or insufficient 2.Remove vapor separator cover; check for proper float level, internal blockage, defectiveparts,and varnish depositsin passages. 3.Check other systems; intakemanifoldfor vacuum leaks, sticking valves, overheating, etc. 4.Check setting and operation plate opening. of throttle (continued on next page) FueiSys/eng 5-30 Engine Fuel System Troubleshooting (cont.) 1. Check for sufficient fuel in tank, blocked tank vent, anti-siphon valve, proper fuel. 2. Check for water or dirt in fuel; check for correct fuel pump pressure/vacuum; check for blockage or air leaks in fuel line. 3. Removevapor separator cover; check float level, float inlet valve operation, internal blockage, varnish, and worn parts. 4. Check for plugged fuel filters. El :1 ~ [el I # i ::11 n]I :~1(o] # | | # I!11 r’_l I_’Te(I,] :~±11 ~ l ~ ~11 [o] # | ~ rzl ~l~oj :11:1 [o] # |[e] ~! | rz~zT~ 1. Check fuel lines for fuel leaks or partially plugged tank vent. 2. Check for water or dirt in fuel; check fuel pump for correct pressure/vacuum. 3. Removevapor separator cover; check for dirt and water; check float level and float inlet valve for operation; check for varnish in passages, worn parts. ~l#l :lv~vl IIg W # [t]liBI ||J -=| #|-’1 =[~e]LV~htd :l~l D] =l~] ~|’J kV~lB 1. Check throttle linkage adjustments to be sure throttle opens fully. 2. Check fuel lines for leaks; check fuel pump for correct pressure/vacuum. 3. Removevapor separator cover; check for dirt and water; check float level and float inlet valve for operation; check for varnish in passages, worn parts. 4. Check boat for proper trim and propeller; check hull for marine growth. 5. Checkignition system components. 6. Checkengine and drive unit for partial seizure. 7. Checkfuel tank for plugged vent; check pickup tube for vacuum leaks. 8. Checkfor plugged fuel filters. 9. Checkfor full opening of throttle. 10. Checkexhaust system for restrictions. 11. Checklower gearcase and propeller for exhaust restrictions. 12. Checkfor restricted air intake. Torque Specifications Circuit Breaker ................. 20-25 in. Ibs. (2,3-2,8 N.m) TBI Fuel Line Nut-to-In/Outlet ............ 17 ft. Ibs. (23 N.m) TBI Fuel Meter Body Inlet .............. 30 ft. Ibs. (40 N.m) TBI Fuel Meter Body Outlet ............. 21 ft. Ibs. (29 N.m) Circuit Breaker ................. 20-25 in. tbs. (2,3-2,8 N.m) Engine Control Module ........... 88-124 in. Ibs. (10-14 N-m) Idle Air Control Valve ................. 28 in. Ibs. (3,2 Nom) Manifold Absolute Pressure Sensor .... 44-62 in. Ibs. (5-7 N.m) TBI Fuel Meter Body ................... 30 in. Ibs. (4 N-m) TBI Fuel Meter Cover ................... 28 in. Ibs. (3 N.m) Throttle Body Injector Unit .............. 12 ft. Ibs. (16 N.m) Throttle Position Sensor ................ 18 in. Ibs. (2 N.m) Engine Coolant Temperature ........... 108 in. Ibs. (12 N.m) Knock Sensor ................... 11-16 ft. Ibs. (15-22 N-m) 5-32 FuelSys.’eng Safety Section 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 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 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... o Products are safe and reliable ... It’s up to you, the people who... ¯ Install accessories... o Service and maintain the boat... ¯ Service and maintain the stern drive... ¯..to keep the products safe and reliable. This section tanks 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 SameStrength? The Same Material? The SameType? Standard or Metric Thread? DR3113 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 componentsto the stern drive. 0 Whenyou remove any part from the stern drive, keep track of special screws and nuts. Don’t mix with other parts. 0 When reassembling the stern drive, 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 eng Stern Drive Shift System The Shift System ,,;tarts here at the remote control lever... . .. and ends here at the propeller. DR3114 What’s Most Important? When control lever is in Forward, Neutral or Reverse "position"... ... Shift mechanism must match control lever "position". DR3114 What Could Happen? o If... Neutral ® if... Forward Forward Reverse or Reverse DR3114 DR3114 ¯ .. 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... e Read, understand, and follow manufacturers instructions. ¯ Closely follow the warnings marked with this symbol, .I~ ... e Assemble parts and make adjustments carefully... e Test your work. Don’t guess. Make sure propeller does just what the operator wants and nothing else. e Do not shift gears when engine is stopped. Adjustments can be lost, and parts weakened. Stern Drive Throttle Control System The Throttle Control System starts here at the remote control lever... ... and ends here on the engine. DR3114 What’s Most Important? When control lever is moved from Forward (or Reverse) to Neutral... ... engine speed must slow to idle RPMand allow operator to shift into Neutral. DR3114 Operator must be able to stop propeller. What Could Happen? If operator cannot slow the engine to idle RPMand 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 this symbol, ~ ... ¯ 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 obtained so operator won’t overload engine. eng S-4 Stern Drive Steering System The Steering System starts here at the steering wheel... ¯.. and ends here at the propeller on the vertical drive. What’s Most Important? DR3114 The Steering System ..¯ ~111 ¯ y| 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.., persons thrown into water could be hit. ff / \ / . k ¯ ... 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 boall control. S-5 How Can Loss of Steering Control be Minimized? In pre-¯ Use steering components which meets marine industry (ABYC) standards.. delivery ¯ Read, understand, and follow manufacturer’s instructions. inspection ® Assemble parts and make adjustments carefully... A and ¯ Closely follow the warnings marked with this symbol, Z_~ ... when ¯ Keep parts moving freely.., lubricate parts as shown in manuals servicing ¯ Use the bolts, nuts, and washers supplied with steering attachment kits.., they’re a special locking type that won’t loosen, rust, or weaken. When power assisted or mechanical steering systems are used, check to uncover possible trouble! ¯ Cable housing in this area ¯ Steering components must must not be restricted not bind Why? Unit may go to full turn without Why? Possible jamming of turning steering wheel (power steer-steering system ing models) DR3475 / // Engine stringer must not interfere DR3470 with power steer- Power steering ing pump and parts and push/pull pulley cable must be free to move in order to actuate power -~ steering valve -~----------------~<---I~ tension ~ Maintain proper belt when operator turns steering wheel DR3472 ¯ Check for damaged parts.., impacts to the vertical drive like this... / ~//~’~’~ DR3128 or this.., or ? ? ? DR3112 ~/,~ can put stress on steering components. Look for ... o Cracked parts e Bent parts o Loose fasteners Replace damaged parts, if weakened,parts could fail later.., on the water ... when least expected. S-6 eng Stern Drive Fuel and Electrical Systems The Electrical here at the baSystem begins ttery... ... at tand ends here ~_. he carburetor. The Fuel starts heSystem re at the fuel tank... ~lp-///"~~ ... and ends IiI~ ~/ ~ here on the en gme. What’s Important? ~ ¯ Fuel leakage must be prevented. ¯ Stray electric sparks must not happen. I~ DR3468 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. A ¯ Closely follow the warnings marked with this symbol Z/.l~ ... ¯ 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 regulation requirements to prevent fire and explosion. if you work on stern drive engines, you must understand these Coast Guard requirements. If you don’t have them, write to... National Technical Information Service Springfield, Virginia 22’161 ... and ask for copies of: DR3109 (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 explosions. ¯ Always use replacement parts specified by the manufacturer. They meet the Coast Guard requirements. Most automotive parts do not, especially electrical components that must meet ignition protection requirements of Coast Guard regulations. ¯ When non-metallic parts look to be in poor shape.., replace them! DR3478 wires cracked boots torn flexible fuel lines cracked Using parts which meet Coast Guard requirements is only half the job. The other half is your job... It’s time for sparks and/or fuel replacement BEFORE leaks occur. Replace parts carefully. Make sure nuts and bolts are tight especially where they anchor electrical wires (to prevent sparking). If Iockwashers are specified -use them. No short cuts 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 build-up of electrostatic sparks. If you use a funnel, makesure it’s metal and ground the fuel nozzle to the funnel. METAL FUNNEL S NEVER... ~~ n°{’/¢~M azkzleetoruech es, 1 DR3110 DR3118 ¯ If you smell gasoline in the engine compartment... find its source and stop the leakage. DR3111 DR3117 S-8 eng ¯ Follow "Starting Procedures" outlined in the operator’s manual. Always make sure there are no gasoJine 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 carburetor. nut tight ’~ Airt i~;~to rSCre~ n DR3115 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 compartment. If fumes are present in compartment, fire and explosion could result. Summing Up Now you know some things that can take the joy out of enjoyable boating. No doubt about.., it takes time! ¯ Reading and understanding instructions. A ¯ Re-reading warnings marked with this symbol ~W ... ¯ Putting parts together right... ¯ Making adjustments right... o Testing your work. and making sure ¯ Worn or damagedparts are replaced, ¯ Replaced parts are like originals.., in every way. o Customer is told of things which need attention... But, Do You Really Want the Alternative? S-10 eog Part B - Marine Products and Safety of People* Who Fix Them Parer 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 stern drives e Troubleshooting problems o Testing their work Some items you’ll know.., others you may not. Handling Engines WhenLifting Engines ¯ Engine may drop suddenly 300 Ibs. if hoist is in poor shape.., or too small for the job 703 Ibs. Ni DR3471 DR3469 ¯ Make sure shop aids have extra capacity .............. and keep them in good repair! When Running Engine with Engine Compartment Cover Removed Engine compartment cover is a guard. When you remove 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 componentscarefully¯ They can shock you and may cause you to recoil into moving parts Two people working together on running engine must look out for each other... Never, ever, hit the key to start engine before signaling your partner. (He may be leaning over the engine with hands on a belt.. ¯ or a "hot" electrical part.., near the propeller.., or ? ? ?) *Mechanics, technicians, backyard do-it-yourselfers. ¯ Exhaust gases 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! Whenyou smell the other gases in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated areas. "~ "/ Eyes Need Help e Grinding -~ ® Sprayed ~-H~ ~1~ Cleaners, --___~" ~----~,o. ¯ Ends of Cab,as /~~ eAc,d "~_~ ¯ Chiseling (steel on steel) (Tip: Use plastic or brass type hammers. Protect Eyes... They don’t chip off as easily as steel hammers.) Wear Safety Glasses ~/.~’__’>~ [/’ \ A Handling Lead Acid Batteries ¯ if spilled or splashed on Strong any part of body.. Acid Solution (Sulfuric Acid) Wash with lots ¯ If solution gets ~’ .~ of water... into eyes... Wash... and see a Doctor, fast! Charging Lead Acid Batteries~~~ [-~’] Attach and remove these cabJes with charger unpluggedfrom 110 volt walt socket. (Prevents shocks if the charger is defective.) Observe correct polarity when connecting these charger leads. ~ ~-~\ l- r~Atways charge in a well ventilated area¯ Charging causes acid solution to give off J hydrogen gas through the vents in the caps... ~ .... ~l~~\J~ Make sure vents are open. If clogged, pressure J-¯ .... inside may build.., battery may explode. S- 12 ~o~ Battery gas is explosive! While charging or discharging, remember... No Smoking No Flames No Sparks Never yank cables off battery posts.., it’s a sure way to make lots of sparks.., surrounded by battery gas. After Charging... Don’t check battery condition by placing metal objects ¯ Shut off charger across posts. ¯ Pull charger plug out of 110V outlet You’re sure to make sparks Then... and serious burns are possible. ¯ ’Take charger" cables off battery posts Gasoline! Handle With Care ® When you smell any odor of gasoline, explosion is possible e Gasoline fumes are heavy and will sink to the lowest point in the boat or room, and will stay there.., waiting Gasoline explodes easily and violently when mixed as shown... ¯ If the air around you is quiet.., the pilot light in the heater may ignite the heavy fumes 5 Parts __.J before your nose ever Gasoline -’---~I smells the fumes... By 100 Parts VolumeAir What Can You Do? ¯ Store properly... ¯ Fill portable tanks outside boat to prevent spillage in Store in sturdy, boatsealed gas can ¯ Use fuel for fuel.., not for a cleaner, degreaser . . . and . . . ¯ If fumes are smelled (in shop, basement, garage), immekeep outside diately: ¯ Put out open flames, cigarettes, sparking devices ¯ Wipe up spill or leak; get lowels, rags outside fast ¯ Check lowest area for fumes; open doors or windows t Know items in and around repair area which can ignite gasoline fumes... Control them if fumes are smelled. ¯ Matches, cigarettes, torches, welders ¯ Enectric motors (with unsealed cases) ¯ Electric generators (with unsealed cases) ¯ Light switches ¯ Appliance pilot lights (furnace, dryer, water heater) ¯ Loose wires on running engines ® 77777777 How many of these are in your area? Hazardous Products Know how items in the shop can hurt people... {;LEANER EGREASF.J DANGER FUEL ADO|IIY£ [)ANGER 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... ¯ ¯ ¯ yummmmmmmm Keep containers away from children -qP VOLVO PENTA MODEL IDENTIFICATION Engine Model identification 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 numbers must 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: Nunberplate for drive unit and transom shield. Only fields 2 and 3 are filled for transom shield. I r=,, xxxx BB X,XX ~ 4 1. Product Designation 2. Model Number 3. Serial Number 4. Reduction Ratio