Clymer 2001-2004 Volvo Penta Stern Drive Shop Manual
Provides service, repair and maintenance information for 2001-2004 Volvo Penta stern drives. Includes models 30GS (3l inline 4 cyl), 43GL, 43GI and 43GXI (4.3L V-6), 50GL, 50EI and 50GXI (5L V-8), 57GS, 57GSI and 57GXI (5.7L V-8), 81GI, GIGXI, DPX375 and DPX420 (8.1L V-8).
Features 688 illustrated pages. The information provided in this book includes:
QUICK REFERENCE DATA
CHAPTER ONE | GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Model
identification | Engine operation | Fasteners | Shop supplies | Galvanic
corrosion | Propellers | Basic tools | Special tools | Precision measuring tools
| Electrical component replacement | Electrical system fundamentals | Basic
mechanical skills | Specifications
CHAPTER TWO | TROUBLESHOOTING
Electrical component replacement | Preliminary inspection | Electric starting
system | Charging system | Ignition system | Basic fuel system troubleshooting |
Carburetor fuel system | Electronic fuel injection (EFI) system | Diagnostic
trouble codes | Power steering system | Power trim electrical system
troubleshooting | Power trim hydraulic system troubleshooting | Cooling system
troubleshooting | Warning system | Engine troubleshooting | Drive system |
Specifications
CHAPTER THREE | LUBRICATION, MAINTENANCE AND TUNE-UP
Before each use | After each use | Lubrication | Fuel system maintenance |
Engine coolant | Tune-up | Submersion | Specifications
CHAPTER FOUR | LAY-UP, WINTERIZING AND FITTING OUT
Lay-up | Winterizing | Fitting out
CHAPTER FIVE | ADJUSTMENTS
Carburetor adjustment | Ignition timing adjustment | Shift cable and linkage
adjustment | Throttle cable adjustment | Trim position sender and trim limit
control module adjustment | Specifications
CHAPTER SIX | ENGINE
Engine operation | Special tools | Replacement parts | Special service
precautions | Engine removal/installation | Engine alignment | Rocker arm cover
| Valve adjustment | Placing the No. 1 piston at TDC (firing position) | Lifter
cover | Camshaft lobe lift measurement | Cylinder head | Rocker arm and pushrod
| Flywheel housing | Drive coupler | Drive plate | Flywheel | Flywheel pilot
bearing | Output drive shaft, seals and bearings | Oil pan | Oil pump | Harmonic
balancer | Timing gear/chain cover | Timing chain and sprockets | Balance shaft
| Camshaft and lifters | Piston and connecting rod | Rear main seal and rear
main seal carrier | Crankshaft | Break-in procedure | Specifications
CHAPTER SEVEN | FUEL SYSTEMS
Fuel system service | Mechanical fuel pump | Low-pressure electric fuel pump |
Carburetor | Electronic fuel injection (EFI) | Intake manifold | Specifications
CHAPTER EIGHT | COOLING AND EXHAUST SYSTEMS
Thermostat | Hose replacement | Recirculation pump replacement | Seawater pump |
Oil and power steering fluid cooler replacement | Exhaust elbow | Exhaust bellow
and flapper valve | Exhaust tube and flapper valve | Exhaust manifold |
Specifications
CHAPTER NINE | ELECTRICAL SYSTEM
Battery | Alternator | Starter motor and solenoid | Starter relay | Fuel pump
relay | EFI system relay | Ignition system | Oil pressure sender | Oil pressure
switch | Engine temperature sender | Engine temperature sensor | Engine overheat
switch | Exhaust overheat switch | Intake air temperature sensor (IAT) |
Throttle position sensor (TPS) | Idle air control motor (IAC) | Knock sensor |
Knock sensor module | Engine control unit (ECU) | Warning horn replacement |
Specifications
CHAPTER TEN | DRIVE UNIT
Drive unit service precautions | Drive unit identification | Drive unit
operation | Drive unit gear ratio | High altitude operation | Outdrive service
precautions | Sacrificial anodes | Shifting and propeller rotation | Propeller |
Drive unit removal and installation | Upper drive shaft housing | Universal
joint | Shift housing service | Pressure and vacuum test | Specifications
CHAPTER ELEVEN | INTERMEDIATE HOUSING AND TRANSOM SHIELD/BRACKET
Intermediate housing operation and inspection | Intermediate housing and
suspension fork | Transom shield and mounting collar | Transom bracket (SX, DP-S
and XDP models) | Transom bracket (DPX models) | Specifications
CHAPTER TWELVE | POWER TRIM SYSTEM
Trim relay | Trim switch fuse | Trim limit control module | Trim motor | Trim
pump | Fluid reservoir | Fluid screen | Hydraulic pump | Relief valve | Trim
cylinder | Trim hose | Trim position sender | Filling and bleeding the trim
system | Specifications
CHAPTER THIRTEEN | STEERING SYSTEM
Safety precautions | Mechanical (manual) steering system | Power steering system
| Specifications
INDEX
WIRING DIAGRAMS
Item: Clymer 2001-2004 Volvo Penta Stern Drive Shop Manual
Item #: B775
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